Hollow Vane Assembly With Brazed Symmetrical Halves
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Solution Overview
Problem
Existing methods for manufacturing hollow vanes, such as casting, fail to meet the dimensional and material requirements necessary for engine operating environments, leading to metallurgical shortfalls.
Innovation Solution
A process involving forming an open body with an interior, creating a cover support structure, forming a cover to attach to the open body, and brazing the cover to the open body to form symmetrical halves, allowing for improved geometric and material compliance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If casting method is used to manufacture hollow vanes, then the hollow cavity can be formed, but the dimensional and material requirements cannot be met
Solution Approach 1:
The vane is divided into two separate halves that are manufactured independently using precision machining or additive manufacturing, then joined together to form the complete hollow vane. This segmentation allows each half to be manufactured with high dimensional precision while avoiding the limitations of traditional casting methods for forming hollow cavities.
2Reliability
If casting method is used to manufacture hollow vanes, then the hollow cavity can be formed, but metallurgical shortfalls occur
Solution Approach 1:
By manufacturing each half separately using superior processes like precision machining or additive manufacturing with controlled metallurgy, the joint between halves becomes a controlled feature rather than a casting defect. This approach eliminates the metallurgical shortfalls inherent in traditional hollow cavity casting while maintaining structural integrity.
3Manufacturing precision
If two piece symmetrical halves are used, then geometric requirements and material compliance are improved, but manufacturing complexity increases
Solution Approach 1:
The design utilizes symmetrical geometry where both halves are identical mirror images, which actually simplifies manufacturing by allowing production of a single half and replication. The symmetry reduces assembly complexity compared to asymmetric designs, as the joining interface is standardized and repeatable.
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 selection of a manufacturing method that meets the geometric requirements of the hardware while reducing metallurgical shortfalls, resulting in a hollow vane assembly with enhanced structural integrity and performance.
Implementation Method 1
brazing the cover to the open body
Data Source
Figure 1
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AI summary
A process of creating a hollow vane assembly (60) comprises forming an open body (62), the open body including an interior (78); forming at least one cover support structure (66) in said open body proximate the interior; forming a cover (64), the cover being configured to attach to the open body to form at least one flow passage (72); forming the open body and the cover as two substantially symmetrical halves; and brazing the cover to the open body. A resulting hollow vane assembly hence comprises: the open body including the interior; the at least one cover support structure formed in the open body proximate the interior; the cover brazed to the open body to form the at least one flow passage; and the open body and the cover configured as the two symmetrically divided halves. A process for improving the stress capability between the cover and the open body for the hollow vane assembly comprises forming the open body, the open body including a leading edge (80) opposite a trailing edge (82), the open body including a pressure side (86) and suction side (84) opposite the pressure side, the open body including the interior; forming the cover, the cover being configured to couple with the open body proximate a centerline (71) of the hollow vane assembly to form at least one flow passage; configuring the open body and the cover as two symmetrically divided halves; and attaching the cover to the open body.