HIP Insert Fixture for Single Crystal Blades

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Solution Overview

Problem

The current hot isostatic pressing (HIP) treatment of single crystal turbine blades is inefficient due to random distribution and contact between blades, leading to localized damage and increased scrappage, as the process does not ensure consistent processing conditions.

Innovation Solution

An insert fixture comprising a lower and upper plate separated by interconnecting members, with the upper plate featuring slots and the lower plate having engagement features to securely position single crystal components, preventing contact and ensuring equal processing conditions, made from materials like alumina ceramic and molybdenum alloys.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If blades are randomly distributed in the basket during HIP treatment, then the process is simple and quick to set up, but contact between blades occurs leading to localized damage and increased scrappage

Engineering Contradiction:

ImproveHIP treatment efficiencyVSAvoidblade quality consistency

Core Design Contradiction:

ProductivityVSReliability

Solution Approach 1:

The insert fixture acts as an intermediary device between the blades and the HIP processing environment. It provides a structured platform with slots and engagement features that hold blades in fixed positions, preventing random distribution and contact between blades during processing.

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The blades are pre-positioned in the insert fixture before HIP treatment begins. The fixture is designed with predetermined slot positions and engagement features that secure blades in optimal orientations, eliminating the need for random placement and ensuring consistent processing conditions from the start.

Inventive Principle:

Principle #10Preliminary action

2Ease of operation

If blades are randomly positioned in the basket, then loading is fast and easy, but processing conditions vary between blades reducing reproducibility

Engineering Contradiction:

Improveblade loading simplicityVSAvoidprocessing condition consistency

Core Design Contradiction:

Ease of operationVSManufacturing precision

Solution Approach 1:

The insert fixture divides the processing space into discrete slots, each designed to hold a single blade in a specific orientation. This segmentation ensures that each blade receives identical processing conditions while maintaining ease of loading through straightforward slot insertion.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Each slot in the insert fixture is designed with specific local features (engagement features, slot dimensions, orientations) tailored to hold blades in the optimal position. This localized design ensures consistent processing conditions for each blade while maintaining overall system simplicity.

Inventive Principle:

Principle #3Local quality

Data Source

PatentUS11725302B2Insert for hot isostatic pressing treatment

Publication Date: 2023.08.15 ROLLS ROYCE PLC

AI summary

An insert fixture for use in the manufacture of a single crystal component by a hot isostatic pressing process. The insert fixture comprising: at least a lower plate separated from an upper plate by interconnecting members. The upper plate comprises at least a slot for the insertion of the single crystal component. The lower plate features a related engagement feature for engaging with the single crystal component. The insert fixture may be cast from a ceramic material. The insert fixture may be cast from an alumina ceramic or molybdenum alloy. The interconnecting members may be made from a molybdenum alloy.