Hollow Vane Cover Composition for Vibration and Stiffness Tuning
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Solution Overview
Problem
Hollow vanes used in gas turbine engines face challenges in meeting dimensional and material requirements due to limitations in casting processes, which affect their vibratory characteristics and adaptability to different operating conditions.
Innovation Solution
A process involving forming an open body with a cover support structure, attaching a cover with brazing, and incorporating plies, such as dampener materials, to modify vibratory characteristics and enhance stiffness, allowing for tailored responses to aerodynamic forces.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If casting process is used to manufacture hollow vanes, then manufacturing capability is improved, but dimensional precision and material requirements are not met
Solution Approach 1:
The vane is divided into two separate components: an open body and a cover. The open body is formed first with internal cooling passages, then the cover is attached to complete the hollow structure. This segmentation allows each component to be manufactured with higher precision using processes better suited to their specific requirements, while the overall manufacturing capability is maintained.
Solution Approach 2:
The invention uses composite construction by combining the open body (formed by casting or additive manufacturing) with a separate cover (formed by additive manufacturing or other processes). This composite approach allows selection of optimal manufacturing processes for each component, achieving both high manufacturing capability and precise dimensional control to meet material requirements.
2Ease of manufacture
If casting process is used to manufacture hollow vanes, then manufacturing capability is improved, but adaptability to operating conditions deteriorates
Solution Approach 1:
The cover is designed with adjustable and reconfigurable features that allow the vane's internal geometry and flow characteristics to be modified based on operating conditions. The cover can be adjusted or replaced to adapt to different thermal and fluid dynamic requirements, providing versatility while maintaining the manufacturing benefits of the segmented construction.
Solution Approach 2:
The open body design with internal cooling passages serves multiple functions: structural support, cooling, and flow management. The cover attaches to complete the hollow structure and can be configured for different operating conditions, making the overall assembly multi-functional and adaptable to various engine operating scenarios while benefiting from efficient manufacturing processes.
3Reliability
If plies with dampener material are added to the cover, then vibratory characteristics are improved, but device complexity increases
Solution Approach 1:
Dampener materials are applied locally at specific positions on the cover where vibratory stresses are highest, rather than throughout the entire structure. This targeted approach improves vibratory characteristics and reliability at critical locations while minimizing the increase in overall device complexity and maintaining manufacturing efficiency.
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 solution enables the modification of vibratory characteristics and stiffness of the hollow vane assembly, optimizing its performance across various operating conditions and extending the life of the vane by redistributing stress and altering modal shapes.
Implementation Method 1
brazing the cover to the open body
Implementation Method 2
disposing a dampener material between an outer layer and an inner layer of the cover to form the at least one ply in the cover
Data Source
AI summary
A hollow vane assembly including an open body including an interior; at least one cover support structure formed in said open body proximate the interior; a cover brazed to the open body to form at least one flow passage; and at least one ply formed in the cover.