Monolithic Turbine Rotor via Thermal Growth Bonding
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Solution Overview
Problem
The existing manufacturing techniques for gas turbine engine components, such as turbine rotors, are costly, complex, and prone to leakage due to the need for multiple precision machining steps and insert-type mating interfaces, which also result in increased size and weight to achieve structural integrity.
Innovation Solution
A method involving the use of arched pieces arranged in a ring formation, bonded together using a directed thermal growth bonding process with a thermal growth constraint tool to form a monolithic ring, which can be bonded onto a separately fabricated rotor disk, reducing complexity and leakage while allowing for a more robust and lighter turbine rotor.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If multiple precision machining steps are used to form the mating blade interface, then the structural integrity and precision of the turbine rotor is improved, but the manufacturing cost and complexity increase
Solution Approach 1:
The patent merges the blade and disk into a single monolithic structure formed from a ring segmentation. This eliminates the need for separate mating interfaces and multiple precision machining steps, as the blade and disk are created as one integrated component through controlled thermal growth bonding of segmented ring pieces.
Solution Approach 2:
The patent segments the ring into multiple pieces that are subsequently bonded together to form the monolithic structure. This segmentation allows for easier manufacturing of individual segments followed by joining, avoiding the complexity of machining complex mating interfaces while maintaining structural integrity.
2Ease of manufacture
If insert-type mating interfaces are used to join blades to the rotor disk, then the turbine rotor can be assembled from separate components, but leakage occurs across the interface
Solution Approach 1:
The patent merges the blade and disk into a single monolithic structure where the blade is an integral part of the disk, formed together from the same material through thermal growth bonding. This eliminates the insert-type mating interface entirely, preventing leakage while maintaining manufacturing feasibility through segmented ring construction.
3Adaptability or versatility
If a multi-piece turbine rotor with mating interfaces is used, then the turbine blades can be fabricated from different alloys than the rotor disk, but the overall size and weight increase to achieve structural integrity
Solution Approach 1:
The patent applies local quality by forming different regions of the monolithic ring (blade region vs. disk region) with different desired properties through selective material placement during segmentation. Each segment can be composed of different alloys or material compositions, which are then bonded together to create a heterogeneous monolithic structure with optimized local properties without requiring additional weight for interfaces.
4Strength
If multiple precision machining steps are used to form the mating interface, then the structural integrity is improved, but the manufacturing time and cost increase
Solution Approach 1:
The patent merges the blade and disk into a monolithic structure formed by thermal growth bonding of segmented ring pieces. This eliminates multiple precision machining steps entirely, as the mating interface is replaced by a continuous monolithic structure. The bonding process achieves strong structural integrity through metallurgical bonding rather than mechanical machining, significantly improving manufacturing efficiency.
Solution Approach 2:
The patent changes the manufacturing parameters from room-temperature precision machining to high-temperature thermal growth bonding. This parameter change transforms the manufacturing process from mechanical removal of material to thermal consolidation, achieving strong structural bonds while reducing the number of processing steps and improving productivity.
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 costs and complexity, minimizes leakage, and results in a more robust and lighter turbine rotor with improved mechanical attachment and performance.
Implementation Method 1
bonding the plurality of arched pieces together to produce a monolithic ring by heating the ring formation to a predetermined bonding temperature
Implementation Method 2
constraining the outward radial growth thereof
Data Source
AI summary
Embodiments of a method (84) for manufacturing a turbine engine component (60) are provided, as are embodiments of a thermal growth constraint tool (118) for the manufacture of turbine engine components (60). In one embodiment, the method (84) includes the steps of obtaining (86) a plurality of arched pieces (88), arranging (110) the plurality of arched pieces (88) in a ring formation (112), and bonding (116) the plurality of arched pieces (88) together to produce a monolithic ring (162) by heating the ring formation (112) to a predetermined bonding temperature while constraining the outward radial growth thereof. Bonding (116) comprises, in turn, positioning a thermal growth constraint ring (120, 122) around the ring formation (112), and heating the ring formation (112) to a predetermined bonding temperature at which the ring formation (112) grows into the thermal growth constraint ring (120, 122).