Mini-Core Bonding With Metered Paste Transfer to Turbine Cores
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Solution Overview
Problem
Current methods for bonding mini-cores to turbine core surfaces are inefficient due to the viscous nature of bonding paste, leading to inconsistent joint interfaces and requiring skilled technicians for manual cleaning and precise paste application, which is labor-intensive and prone to errors.
Innovation Solution
A method involving mini-cores with attachment devices such as protrusions, posts, or bumpers that are dipped into a controlled amount of paste and affixed to the core surface, forming a fillet at the base, allowing for a consistent and automated bonding process with a paste of controlled viscosity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If paste is metered into the hole or recess to bond the mini-core, then the joint interface quality improves, but the process becomes difficult and time-consuming due to the viscous nature of the paste requiring skilled technicians
Solution Approach 1:
The paste is applied to the protrusion before insertion into the hole, ensuring the correct amount is pre-loaded. This preliminary action eliminates the difficulty of metering paste during the bonding process itself, as the paste is already in position and the correct quantity before the actual joint formation occurs.
Solution Approach 2:
The protrusion serves as an intermediary carrier for the paste. Instead of directly metering paste into the hole (which is difficult due to viscosity), the paste is first applied to the protrusion, which then transfers it into the hole during insertion. This intermediary step simplifies the overall process.
2Manufacturing precision
If manual cleaning of the bond area is performed to ensure proper bonding, then the joint quality improves, but the process becomes labor intensive and variable
Solution Approach 1:
The bond area is cleaned before paste application, ensuring the surface is ready for bonding. This preliminary cleaning action eliminates the need for repeated cleaning during the process, reducing labor intensity while maintaining joint quality.
Solution Approach 2:
The process is designed to be self-contained, with all necessary actions (cleaning, paste application, bonding) completed in a single sequence without requiring intermediate interventions or adjustments, thereby improving productivity while maintaining quality consistency.
3Reliability
If the paste is thickened with filler to prevent shrink, then the joint reliability improves, but the paste becomes hard to work with and does not flow well
Solution Approach 1:
The paste is applied to the protrusion before insertion, allowing it to be positioned exactly where needed. This preliminary application eliminates the need for the paste to flow extensively during bonding, so even thickened paste with fillers can be effectively used without handling difficulties.
Solution Approach 2:
The paste is concentrated locally on the protrusion rather than being spread out. This localized application means the paste doesn't need to flow over large distances, making it easier to work with even when thickened with fillers for shrink prevention.
4Manufacturing precision
If a skilled technician performs the bonding process carefully, then the joint detail quality improves, but the time required increases significantly
Solution Approach 1:
The protrusion is pre-loaded with the correct amount of paste before insertion into the hole. This preliminary preparation eliminates the need for careful, time-consuming paste metering during the actual bonding process, reducing the time required while maintaining joint detail quality.
Solution Approach 2:
The process is designed to be self-contained and straightforward, requiring minimal skilled intervention. The pre-loaded protrusion automatically provides the correct paste amount, reducing reliance on technician skill and experience, thereby reducing bonding time while maintaining quality.
Data Source
AI summary
A method of bonding a mini-core to a surface of a core is provided. The method includes providing the mini-core with an attachment device that includes a protrusion of a surface of the mini-core, dipping the protrusion into a supply of paste to transfer a fixed quantity of paste to the protrusion and affixing the protrusion to the surface of the core with the fixed amount of paste interposed between the surface and the protrusion.