Multi-Zone Turbine Blade Joining With Field-Assisted Sintering
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Solution Overview
Problem
Existing methods for manufacturing gas turbine engine blades, particularly in high-temperature sections, face challenges in achieving efficient multi-material blade construction without compromising structural integrity or increasing production complexity.
Innovation Solution
A method involving casting multiple zones of different alloys, assembling these zones, applying a load, and using field-assisted sintering technology (FAST) to fuse the zones together by applying current across their junction, while optionally heating and using temperature feedback control to manage the process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If multi-material blade construction is used to optimize material properties for high-temperature sections, then thermal resistance and structural integrity are improved, but manufacturing complexity increases
Solution Approach 1:
The blade is divided into multiple cast portions (first cast portion and second cast portion) that can be manufactured separately and then assembled together. This segmentation allows each portion to be optimized for specific material properties while simplifying the overall manufacturing process by enabling parallel production of individual segments before final assembly through field-assisted sintering.
Solution Approach 2:
The invention employs multi-material construction by casting different alloy compositions in different portions of the blade. The first cast portion and second cast portion can have different material properties optimized for their specific locations, creating a composite structure that enhances thermal resistance and structural integrity while managing the complexity through standardized joining procedures.
2Strength
If field-assisted sintering technology is used to fuse cast portions, then bonding strength is improved, but process complexity increases
Solution Approach 1:
The invention replaces traditional mechanical joining methods with field-assisted sintering technology that uses electrical current and controlled heating to fuse the cast portions. This substitution achieves superior bonding strength by creating metallurgical bonds rather than mechanical connections, while the automated control of the sintering process helps manage the complexity through standardized procedures.
Solution Approach 2:
The field-assisted sintering process utilizes controlled changes in temperature, electrical current, and pressure parameters to achieve optimal bonding. By systematically managing these parameters through feedback control, the process achieves high bonding strength while reducing variability and complexity through standardized parameter sets for different blade configurations.
3Reliability
If multiple cast portions are assembled and fused, then material optimization is improved, but production time increases
Solution Approach 1:
The cast portions are manufactured separately in advance through parallel casting processes, allowing material optimization for each specific portion without waiting for other portions to be ready. This preliminary action enables simultaneous production of multiple blade segments, reducing overall production time while maintaining material optimization benefits.
Solution Approach 2:
The field-assisted sintering process continuously fuses the cast portions in a single integrated operation rather than using multiple discrete bonding steps. This continuous action reduces production time by eliminating intermediate handling and setup operations, while the automated control ensures consistent quality throughout the fusion process.
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 method enables the creation of turbine engine blades with optimized material properties across different zones, enhancing thermal resistance and structural integrity while simplifying the manufacturing process.
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.
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.