Green Part Shaping via Local Heating for Turbine Panels
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Manufacturing complex gas turbine engine panel elements, such as combustor heat shield panels with curved shapes and angled features, is challenging using traditional molding processes due to the need for complex mold configurations, making powder injection molding impractical.
Innovation Solution
The method involves molding the panel in an initial shape with a reduced complexity, allowing for deformation to the final shape using local heating and shaping, which simplifies the mold configuration and enables the creation of angled features without requiring complex mold designs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If traditional molding processes are used to manufacture complex-shaped panels with angled features, then the final product shape can be achieved, but the mold configuration becomes overly complex making the process impractical
Solution Approach 1:
The manufacturing process is segmented into distinct stages: initial molding of a simplified green part, followed by selective removal of binder material from specific regions, and final shaping. This segmentation allows the mold to remain simple while achieving complex final geometries through subsequent processing steps.
Solution Approach 2:
The green part is preliminarily molded with a simplified geometry that is easier to manufacture than the final complex shape. This preliminary action allows the use of simple mold cavities, and the complex features are added later through selective binder removal and shaping operations.
2Manufacturing precision
If a complex mold configuration is used to manufacture panels with curved shapes and angled retention members, then the desired features can be molded, but the manufacturing cost and complexity increase significantly
Solution Approach 1:
Binder removal is applied locally to specific regions of the green part rather than uniformly throughout. This local treatment allows retention members and other features to maintain their required precision in critical areas while allowing flexibility in regions where complex mold features would be needed.
Solution Approach 2:
The physical and chemical parameters of the green part are changed through controlled binder removal, transforming the material properties in specific regions to enable shaping operations. This allows the part to be deformed into complex shapes after molding without requiring complex mold cavities.
3Adaptability or versatility
If powder injection molding is used to manufacture elements with angled cooling holes and retention members, then the features can be integrated into the part, but the process becomes impractical due to mold complexity
Solution Approach 1:
The features are segmented into two categories: those formed during initial molding (basic geometry) and those created through subsequent binder removal and shaping (complex geometry). This segmentation allows the mold to remain simple while still achieving full feature integration through the combined process steps.
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 allows for the successful production of complex-shaped panels with angled features using simpler mold cavities, reducing manufacturing costs and complexity while maintaining the integrity of the final product.
Implementation Method 1
removal of a binder material from at least a portion of the green part
Implementation Method 2
deformation of the green part from an initial shape to a final shape
Data Source
Figure 1
Figure 2
Figure 3a
AI summary
A method of shaping a part (28) in a green state obtained through powder injection molding, including placing a surface of the part (28) in contact with a shaping surface (48) of a setter (46) with at least one section (36) of the surface of the part (28) not conforming to the shaping surface (48), and locally heating at least one area (50) of each of the at least one section (36) to deform the part (28) until the at least one section (36) conforms to the shaping surface (48). The part (28) remains in the green state during the local heating. The part (28) may be a heat shield panel for a gas turbine engine.