Multi-Zone Turbine Blade Joining for Alloy Bond Integrity
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Solution Overview
Problem
Current methods for manufacturing gas turbine engine blades, particularly in high-temperature sections, face challenges in effectively bonding multi-material blades without compromising their structural integrity or thermal properties, especially when using different alloys and single crystal structures.
Innovation Solution
A method involving casting multiple alloy zones of a gas turbine engine blade, where a first and second cast portion are assembled and fused using a combination of pressure and electrical current, with simultaneous heating and feedback control, to ensure strong bonding without melting or deforming the materials, while machining cooling channels and removing transition regions to minimize thermal expansion issues.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If multi-material blades are manufactured using bi- and tri-casting methods, then thermal performance is improved, but bonding integrity between different alloys is compromised
Solution Approach 1:
The blade is divided into multiple cast portions (first cast portion and second cast portion) made of different alloys, allowing each segment to be optimized for specific thermal conditions while maintaining overall structural integrity through controlled bonding interfaces
Solution Approach 2:
The bonding process utilizes controlled application of load and electrical current with simultaneous heating and feedback control to fuse cast portions at their junction, transforming the bonding parameters to achieve strong metallurgical bonds between different alloys without compromising integrity
2Adaptability or versatility
If separately manufactured sections are welded or bonded to create multi-material blades, then manufacturing flexibility is improved, but structural integrity at junctions deteriorates
Solution Approach 1:
The bonding process replaces conventional welding with a field-assisted sintering approach using electrical current and controlled heating, eliminating the need for mechanical welding operations while achieving superior metallurgical bonds that maintain single crystal structure integrity
Solution Approach 2:
The bonding process incorporates feedback control to monitor and adjust the application of load and current during fusing, ensuring optimal bonding conditions are maintained throughout the process to achieve consistent structural integrity at junctions
3Strength
If field assisted sintering technology is used for bonding, then bonding strength is improved, but process complexity increases
Solution Approach 1:
The bonding process merges heating, pressurization, and electrical current application into a single integrated field-assisted sintering operation, achieving strong bonds while consolidating multiple process steps into one unified operation that reduces overall process complexity
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 the creation of robust, multi-material blades with improved thermal performance and structural integrity, allowing for efficient energy transfer and reduced risk of thermal stress, thereby enhancing the operational efficiency of gas turbine engines.
Implementation Method 1
applying current across a junction of the first cast portion and the second cast portion to fuse the second cast portion to the first cast portion
Implementation Method 2
A recent technology in sintering of powder-formed bodies is field assisted sintering technology (FAST), also known as spark plasma sintering. This involves a combination of heat, pressure, and current.
Implementation Method 3
heating the first cast portion of the airfoil and the second cast portion of the airfoil
Implementation Method 4
applying a load across the assembly of the first cast portion of the airfoil and the second cast portion of the airfoil
Data Source
AI summary
In a method for manufacturing a turbine engine element such as a blade or vane, the element has an airfoil. The method includes: applying a load across an assembly of a first cast portion of the airfoil and a second cast portion of the airfoil; and applying current across a junction of the first cast portion and the second cast portion to fuse the second cast portion to the first cast portion.