Directional Solidification of Metallic Truss Structures

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Solution Overview

Problem

Current turbine rotor blade manufacturing methods fail to efficiently produce high-temperature, lightweight components with tailored crystallographic orientations for enhanced structural properties and cooling efficiency.

Innovation Solution

A method involving the directional solidification of a truss structure with spaced face sheets and columnar structures, formed using a 3D pattern and mold core, allowing for the creation of single crystal or directionally solidified materials with controlled crystallographic orientations, which are then used in the production of rotor blades with improved cooling and structural characteristics.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If traditional casting methods are used to produce turbine blades, then manufacturing simplicity is maintained, but crystallographic orientation control and structural properties are insufficient

Engineering Contradiction:

Improvecrystallographic orientation controlVSAvoidcasting process complexity

Core Design Contradiction:

Manufacturing precisionVSDevice complexity

Solution Approach 1:

A pre-formed pattern with the desired truss structure geometry is created before casting. This pattern serves as a template that guides the directional solidification process, ensuring that the final casting achieves the complex crystallographic orientations and truss structure geometry required for high-temperature performance without needing complex real-time control during casting

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The casting process utilizes controlled directional solidification by changing temperature gradients and cooling rates. By carefully controlling the solidification parameters, the method achieves single-crystal or directionally-solidified microstructures with specific crystallographic orientations aligned with the truss structure, thereby improving high-temperature resistance and structural properties

Inventive Principle:

Principle #35Parameter changes

2Temperature

If turbine blades are made hollow with internal cooling cavities, then cooling efficiency is improved, but weight and structural complexity increase

Engineering Contradiction:

Improvehigh-temperature resistanceVSAvoidblade weight

Core Design Contradiction:

TemperatureVSWeight of moving object

Solution Approach 1:

The invention employs a truss structure with inherent porosity and internal channels formed during directional solidification. This porous truss architecture provides cooling pathways without requiring separate hollow cavities, thereby improving heat dissipation while maintaining lower weight compared to traditional hollow blade designs

Inventive Principle:

Principle #31Porous materials

Solution Approach 2:

The method produces a composite microstructure combining a truss framework with directionally-solidified or single-crystal metallic material. This composite structure integrates structural load-bearing functions with thermal management capabilities, achieving high-temperature resistance without the need for additional cooling system components that would increase weight

Inventive Principle:

Principle #40Composite materials

3Adaptability or versatility

If multiple welding or joining operations are used to assemble rotor blades, then structural flexibility is improved, but manufacturing time and cost increase

Engineering Contradiction:

Improvestructural configuration flexibilityVSAvoidmanufacturing efficiency

Core Design Contradiction:

Adaptability or versatilityVSProductivity

Solution Approach 1:

The invention integrates the truss structure geometry, cooling channels, and structural support functions into a single monolithic casting component. By combining multiple functions that would traditionally require separate parts and welding operations into one directional solidification casting process, the method eliminates joining steps while maintaining structural flexibility through the integrated truss design

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The directionally-solidified truss structure serves multiple functions simultaneously: it provides structural support, enables cooling fluid flow through its internal geometry, and achieves high-temperature resistance through its crystallographic orientation. This multi-functional design eliminates the need for separate components and joining operations, thereby improving manufacturing efficiency

Inventive Principle:

Principle #6Universality (Multi-functionality)

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 method enables the production of rotor blades with superior high-temperature resistance, lightweight design, and enhanced cooling efficiency, leading to improved performance and extended lifespan while being cost-effective and reducing the need for welds or joints.

Implementation Method 1

directionally solidifying the liquid alloy to form the casting of the truss structure

Methodology Applied

Scientific EffectDirectional solidification: Crystallisation

Data Source

PatentUS9975175B2Metallic structure

Publication Date: 2018.05.22 GENERAL ELECTRIC CO

AI summary

A method of casting a truss structure having spaced face sheets connected by columnar structures, including forming a three-dimensional pattern (3D pattern) in the shape of the truss structure with the spaced face sheets and columnar structures, forming a mold core of the 3D pattern by surrounding the pattern with a liquid and letting the liquid harden about the 3D pattern, removing the 3D pattern from the mold core, filling the mold core with a liquid alloy to cast and directionally solidify the truss structure.