Multi-Component Hydrostatic Seal Assembly for Low-Leakage Manufacturing
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Solution Overview
Problem
Traditional methods for manufacturing hydrostatic advanced low leakage seals in gas turbine engines, such as wire EDM, are time-consuming and costly, and result in a rough surface finish that limits design space and increases material waste.
Innovation Solution
The method involves manufacturing multiple separate components using different processes, such as machining and additive manufacturing, and assembling them using techniques like brazing, adhesive bonding, or welding, to form a hydrostatic advanced low leakage seal with independently manufactured shoe, beams, and base portions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If wire EDM manufacturing process is used, then the seal can be manufactured with complex internal geometry, but the manufacturing time and cost increase significantly
Solution Approach 1:
The seal is divided into multiple separate components (shoe, beams, base portion) that are manufactured independently using different processes. The shoe and base portion can be manufactured using additive manufacturing or machining, while beams are manufactured separately and then assembled together, eliminating the need for time-consuming wire EDM operations on the entire structure.
Solution Approach 2:
Different manufacturing processes (additive manufacturing, machining, welding) are combined to manufacture various components of the seal. This allows each component to be optimized for its specific manufacturing process, achieving complex geometries where needed while maintaining high productivity for other parts.
2Shape
If wire EDM manufacturing process is used, then the seal can be manufactured with complex internal geometry, but the manufacturing cost increases
Solution Approach 1:
The seal is divided into multiple separate components (shoe, beams, base portion) that are manufactured independently using different processes. The shoe and base portion can be manufactured using additive manufacturing or machining, while beams are manufactured separately and then assembled together, eliminating the need for time-consuming wire EDM operations on the entire structure.
Solution Approach 2:
The manufacturing approach changes from a single process (wire EDM) to multiple processes (additive manufacturing, machining, welding). This parameter change in the manufacturing method allows for cost-effective production while maintaining the ability to create complex geometries where required.
3Shape
If wire EDM is used to cut beams, then the internal geometry can be created, but the cut surface has material debit due to rough surface
Solution Approach 1:
The seal is divided into multiple separate components (shoe, beams, base portion) that are manufactured independently using different processes. The shoe and base portion can be manufactured using additive manufacturing or machining, while beams are manufactured separately and then assembled together, eliminating the need for time-consuming wire EDM operations on the entire structure.
Solution Approach 2:
The mechanical wire EDM cutting process is replaced with alternative manufacturing methods such as additive manufacturing or traditional machining for the shoe and base portion. These alternative processes produce superior surface finishes without the material debit associated with wire EDM, while still achieving the required internal geometries.
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 reduces manufacturing and assembly costs, allows for thinner beams to increase resonant frequency, and decouples shoe and spring lengths, enhancing seal performance and design flexibility while maintaining low leakage and long life.
Implementation Method 1
The hybrid seal tracking surface is attached to a solid carrier ring via continuous thin beams. These beams enable the low resistance movement of the hybrid seal in a radial direction.
Implementation Method 2
the first beam is brazed to the shoe and the base portion
Data Source
Figure 1
Figure 2
Figure 3~4
AI summary
A method of manufacturing a hydrostatic advanced low leakage seal (100) configured to be disposed between relatively rotatable components is provided. The method includes manufacturing a plurality of separate, independent components (180, 182) of the seal. The method also includes assembling the plurality of separate, independent components to form the seal (100).