Multi-Alloy Bladed Turbine Stator for Stress Optimization
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Solution Overview
Problem
The existing bladed turbine stators in aircraft turbine engines are optimized with a single metal alloy for all blades, which does not account for the varying mechanical stresses across different sectors, leading to suboptimal performance and mechanical strength.
Innovation Solution
The bladed turbine stator is designed with blades made of two different metal alloys, where first blades subjected to higher stress are made of a stronger alloy like René125, and second blades under lower stress are made of a lighter and less expensive alloy like René77, optimizing material usage based on stress levels.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a single metal alloy is used for all blades in a bladed stator, then the manufacturing process is simplified and cost is reduced, but the mechanical strength and performance are suboptimal because varying stress levels across different sectors are not accounted for
Solution Approach 1:
The patent applies local quality by using different metal alloys for different blades within the same bladed stator based on their specific stress levels. Blades in high-stress sectors use a first metal alloy optimized for strength, while blades in low-stress sectors use a second metal alloy optimized for weight reduction. This allows each blade to have material properties tailored to its local mechanical environment, resolving the contradiction between overall strength and material complexity.
2Weight of moving object
If blades are made with optimized material distribution based on stress levels, then weight is reduced and aerodynamic performance is improved, but the manufacturing complexity increases
Solution Approach 1:
The patent implements local quality by selectively applying different metal alloys to different blades based on their stress characteristics. This allows weight optimization by using lighter materials where structurally feasible, while maintaining necessary strength in high-stress areas. The manufacturing process is adapted to accommodate multiple materials through sector-based production and selective material application.
Solution Approach 2:
The bladed stator is segmented into multiple sectors, each potentially containing blades made of different metal alloys. This segmentation allows independent material selection and manufacturing optimization for each sector, making the complex multi-material construction manageable through modular production approaches.
3Productivity
If all blades use the same metal alloy, then cost is reduced and manufacturing is simplified, but performance efficiency is compromised due to non-optimized material selection for specific stress conditions
Solution Approach 1:
The patent achieves performance efficiency through local quality optimization by matching material properties to local stress conditions. Blades experiencing higher stresses use metal alloys with superior strength characteristics, while blades in lower-stress regions use materials optimized for weight and cost. This localized optimization resolves the contradiction between overall performance efficiency and material differentiation complexity.
Data Source
AI summary
A turbine nozzle for a turbine engine, including two annular walls extending about the same axis, the walls being connected to each other by blades having an aerodynamic profile, the nozzle being divided into sectors and including several nozzle sectors arranged circumferentially end-to-end about a longitudinal axis. The blades include first blades made from a first metal alloy, and second blades made from a second metal alloy different from the first alloy, each nozzle sector including first blades and second blades. The invention also relates to a turbine engine, in particular of an aircraft, including at least one such nozzle. The invention also relates to a method for manufacturing such a nozzle in which each of the sectors is produced, for example, by additive manufacturing.