Additive Manufacturing Integral Stator Airfoil Assemblies
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Solution Overview
Problem
Conventional turbine engines face durability issues and limited operational temperature due to complex 3D configurations of stator airfoils and rotor blades, which restrict efficient energy extraction and cooling air configurations.
Innovation Solution
The use of additive manufacturing techniques, specifically direct metal laser fusion, to create stator airfoil assemblies as integral structures without weld or braze joints, allowing for optimized internal cooling circuits and flange configurations that enhance thermal and mechanical compliance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional manufacturing techniques are used to manufacture stator airfoils with complex 3D configurations, then manufacturing precision can be maintained, but device complexity increases and durability decreases due to required weld or braze joints
Solution Approach 1:
The patent combines multiple separate components (airfoil exterior, airfoil interior, internal ribs, cooling circuits) into a single integrated structure manufactured by additive manufacturing. This eliminates the need for weld or braze joints between components, directly resolving the technical contradiction by improving reliability through integration while maintaining the complex 3D configuration through advanced manufacturing capabilities
2Productivity
If conventional manufacturing techniques are used, then manufacturing processes are well-established, but productivity decreases due to complex assembly processes involving multiple parts and joining operations
Solution Approach 1:
The patent integrates multiple manufacturing operations into a single additive manufacturing process. The airfoil exterior, airfoil interior, internal ribs, and cooling circuits are all formed simultaneously in one build process, eliminating sequential assembly operations and significantly improving productivity despite the complexity of the final geometry
3Loss of substance
If traditional assembly methods with multiple components are used, then ease of manufacture is maintained through standardized parts, but loss of substance increases due to material waste from joining operations and flash
Solution Approach 1:
The patent uses additive manufacturing to create the entire stator airfoil assembly as a single integral structure, eliminating material waste associated with joining operations (weld flash, braze material, adhesive). The additive process only deposits material where needed, significantly reducing material loss compared to subtractive or assembly-based conventional manufacturing
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 higher temperature operation, improved durability, and reduced manufacturing costs by eliminating the need for complex assembly processes and allowing for unique cooling designs that optimize airflow and thermal management.
Implementation Method 1
forming an interior wall of a stator airfoil using an additive manufacturing technique, forming an exterior wall of the stator airfoil using the additive manufacturing technique, and forming a plurality of internal ribs between the interior wall and the exterior wall using the additive manufacturing technique
Implementation Method 2
The use of additive manufacturing techniques, specifically direct metal laser fusion, to create stator airfoil assemblies as integral structures
Data Source
Figure 1
Figure 2A~2B
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AI summary
In accordance with an exemplary embodiment, a method of manufacturing a stator airfoil assembly includes forming an interior wall of a stator airfoil using an additive manufacturing technique, forming an exterior wall of the stator airfoil using the additive manufacturing technique, and forming a plurality of internal ribs between the interior wall and the exterior wall using the additive manufacturing technique. A cooling air circuit is formed in a space between the interior wall and the exterior wall. Further, the interior wall, the exterior wall, and the internal ribs are formed simultaneously as an integral structure by using the additive manufacturing technique.