Additive Manufacturing Grain Size Control for Thin Turbine Casings
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Solution Overview
Problem
Current additive manufacturing techniques produce parts with a single grain size across the entire component, compromising between strength/fatigue properties and creep performance, and are inadequate for thin, structurally sensitive parts like aircraft turbine engine casings that require tailored grain sizes based on localized mechanical properties and operating conditions.
Innovation Solution
An additive manufacturing environment that uses a combination of controlled heat sources and force application devices, such as rollers, to deposit materials in layers with varying grain sizes, allowing for the creation of components with tailored grain structures that match specific mechanical properties and operating conditions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a single grain size is used across the entire component, then manufacturing simplicity is maintained, but mechanical properties and creep performance are compromised
Solution Approach 1:
The patent applies local quality by varying grain size parameters in different regions of the component based on localized mechanical properties and operating conditions. The additive manufacturing process enables different grain sizes to be produced in different areas, allowing each region to have optimal mechanical properties tailored to its specific functional requirements rather than using a uniform grain size throughout the entire component.
2Ease of manufacture
If a single grain size is used across the entire component, then manufacturing simplicity is maintained, but creep performance deteriorates
Solution Approach 1:
The patent applies local quality by varying grain size parameters in different regions of the component based on localized mechanical properties and operating conditions. The additive manufacturing process enables different grain sizes to be produced in different areas, allowing each region to have optimal mechanical properties tailored to its specific functional requirements rather than using a uniform grain size throughout the entire component.
3Strength
If tailored grain sizes are produced in different regions, then mechanical properties and creep performance are optimized, but device complexity increases
Solution Approach 1:
The patent applies parameter changes by modifying grain size parameters during the additive manufacturing process to achieve tailored grain structures. By controlling processing parameters such as laser power, scanning speed, and layer thickness in different regions, the process produces components with spatially varying grain sizes that optimize mechanical properties and creep performance for specific application requirements.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach enables the production of components with optimized grain sizes across different regions, enhancing both strength and creep performance while reducing weight, particularly beneficial for thin parts like low-pressure turbine casings in aircraft engines.
Implementation Method 1
DED allows for the creation of 3D objects by melting the material in powder or as a wire with a focused energy source as it is deposited by the nozzle of the AM device
Implementation Method 2
as the materials cool/cure, the materials fuse together to form the final 3D object
Data Source
AI summary
Methods, apparatus, systems, and articles of manufacture are disclosed to generate a tailored grain size in an additive manufacturing environment. Disclosed herein is an apparatus comprising controller circuitry to determine a configuration for manufacture of a part, the part having a first portion and a second portion, an additive manufacturing machine to manufacture the part according to the configuration, and a force application device to apply a force to the part during manufacture, the force specified in the configuration to produce a desired grain size, the desired grain size including a first grain size and a second grain size, wherein the first portion is formed with the first grain size and the second portion is formed with the second grain size.