HIP Abrasive Turbine Blade Tip for Long-Term Wear Resistance
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Solution Overview
Problem
Existing methods for producing abrasive tips for turbine blades are not durable for long-term engine use due to limitations in blade tip design resulting from fabrication techniques, leading to significant wear and reduced compressor or turbine performance.
Innovation Solution
A method involving mixing metal powder with abrasive ceramic powder, sealing the mixture in a metallic mold, and subjecting it to a hot isostatic pressing process to compact and bind the mixture into a solid airfoil shape, which is then sliced and bonded to the turbine blade using diffusion or transient liquid phase bonding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional fabrication methods (electroplating or metal powder mixing) are used to produce abrasive tips, then the blade tip can be manufactured with abrasive material, but the durability and reliability of the abrasive tip for long-term engine use is reduced
Solution Approach 1:
The invention changes the manufacturing parameters by using hot isostatic pressing (HIP) instead of traditional electroplating or simple mixing methods. This process applies high pressure and temperature to densify the metal matrix and securely embed abrasive particles, creating a more durable composite structure that maintains reliability under long-term engine operating conditions
Solution Approach 2:
The invention creates a composite material structure by combining metal powder with abrasive ceramic particles in a controlled matrix. This composite approach allows the abrasive tip to maintain both the structural integrity of the metal and the cutting properties of the abrasive particles, significantly improving durability compared to surface coatings or simple mixtures
2Productivity
If blade tip dimensions are tightly controlled to minimize clearance, then compressor or turbine efficiency is improved, but the blade tip becomes more susceptible to wear from interference rubs with the shroud
Solution Approach 1:
The invention applies local quality by providing abrasive material specifically at the blade tip region where contact with the shroud occurs. This localized abrasive layer protects the critical tip area from wear while maintaining the tight clearance dimensions needed for high compressor or turbine efficiency, allowing the blade to tolerate interference rubs without significant wear
3Object-affected harmful factors
If abrasive particles are embedded in the blade tip using prior art methods, then some abrasive protection is achieved, but the abrasive tip is not durable for long-term engine use due to design limitations
Solution Approach 1:
The invention applies preliminary action by pre-embedding durable abrasive particles into the blade tip matrix during the manufacturing process using hot isostatic pressing. This preliminary incorporation of abrasive material creates a robust composite structure that provides sustained protective action throughout the service life of the turbine engine, eliminating the need for frequent replacement or maintenance
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
The method produces a durable abrasive tip that minimizes wear and maintains compressor or turbine performance by allowing for a more robust blade tip design, enhancing the durability and efficiency of turbine engines.
Implementation Method 1
subjecting the sealed mold to a hot isostatic pressing process. The hot isostatic pressing process compacts and binds the metal and ceramic powder mixture together into a solid article
Implementation Method 2
sealing the metal and ceramic powder mixture within the hollow interior portion of the metallic mold under vacuum
Implementation Method 3
bonding one slice of the plurality of airfoil-shaped slices to a tip portion of a turbine blade
Implementation Method 4
bonding one slice of the plurality of airfoil-shaped slices to a tip portion of a turbine blade using diffusion or transient liquid phase bonding
Data Source
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AI summary
A method of producing an abrasive tip for a turbine blade (150) includes producing or obtaining a metal powder that is mixed with an abrasive ceramic powder and producing or obtaining a metallic mold (200) that is in the shape of an airfoil (152). The metallic mold (200) includes a hollow interior portion. The method further includes sealing the metal and ceramic powder mixture within the hollow interior portion of the metallic mold under vacuum and subjecting the sealed mold to a hot isostatic pressing process. The hot isostatic pressing process compacts and binds the metal and ceramic powder mixture together into a solid article in the shape of the airfoil. Still further, the method includes slicing the solid article into a plurality of airfoil-shaped slices and bonding one slice of the plurality of airfoil-shaped slices to a tip portion of a turbine blade.