Nested Segment Assemblies for Turbine Engine Shroud Hangers
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Solution Overview
Problem
The assembly of segmented ring components in turbine engines, such as shroud hangers, is time-consuming and difficult due to the need for precise alignment and connection of machined slots and spline seals, particularly when forming an annular ring.
Innovation Solution
An additively manufactured nested segment assembly is developed, where a first component segment with a tongue is nested within a groove of a second component segment, with the tongue having a height greater than the groove's opening height to ensure inseparable joining, and featuring turbulators to reduce leakage through a tortuous flow path.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional machining of slots and assembly of spline seals is used, then reliable sealing is achieved, but assembly time and complexity increase significantly
Solution Approach 1:
The patent merges the sealing function and the structural connection function into a single integrated feature. The tongue and groove assembly is formed as one piece through additive manufacturing, eliminating the need for separate spline seals and slot machining operations while maintaining effective sealing through the integrated design.
Solution Approach 2:
The patent replaces traditional mechanical assembly methods (machining slots, inserting spline seals, manual alignment) with additive manufacturing. This substitution eliminates multiple manual operations and reduces assembly complexity while achieving the same sealing reliability through the digitally fabricated integrated structure.
2Ease of manufacture
If multiple separate components are assembled, then manufacturing flexibility is maintained, but assembly difficulty and alignment precision requirements increase
Solution Approach 1:
The patent combines multiple functional features (sealing surface, structural connection, alignment) into a single integrated tongue and groove assembly that is manufactured as one piece. This reduces the number of parts to be assembled and eliminates alignment difficulties while maintaining manufacturing flexibility through additive manufacturing.
Solution Approach 2:
The patent segments the shroud hanger into modular sections that can be independently manufactured using additive manufacturing, then assembled together. This segmentation maintains manufacturing flexibility for complex geometries while simplifying assembly compared to traditional machining approaches, as each segment can be fabricated with built-in alignment features.
3Ease of manufacture
If conventional manufacturing methods are used, then established processes are maintained, but complex nested shapes and monolithic structures cannot be achieved
Solution Approach 1:
The patent replaces conventional mechanical manufacturing (machining, welding, assembly) with additive manufacturing to create complex nested shapes and monolithic structures. The digital modeling and layer-by-layer fabrication process enables geometric complexities that are impossible to achieve with traditional methods while maintaining process reliability through controlled manufacturing parameters.
Solution Approach 2:
The patent implements nested structures where one component fits within another, creating compact and efficient geometries. The additive manufacturing process naturally accommodates these nested configurations, allowing complex internal structures and optimized material distribution that would be extremely difficult to produce using conventional manufacturing methods.
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 solution simplifies the assembly process by forming inseparable monolithic components that allow for thermal growth and reduce leakage, while enabling the creation of complex shapes and structures not possible with traditional manufacturing methods, improving assembly efficiency and component reliability.
Implementation Method 1
directing energy from an energy source of the additive manufacturing machine to successively fuse one or more layers of additive material on top of the layer of additive material to form the nested segment assembly
Implementation Method 2
the tongue comprises a plurality of turbulators projecting therefrom
Data Source
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AI summary
A nested segmented assembly (100) and a method (300) of additively manufacturing the same are provided. In one example aspect, the assembly (100) includes a first component segment (110) and a second component segment (112) positioned adjacent the first component segment (110). The first component segment (110) has an end face and a tongue (130) projecting outwardly from the end face (128). The second component segment (112) defines a groove (132). The groove (132) is defined at an end face (126) of the second component segment (112) that is adjacent the end face (128) of the first component segment (110). The first component segment (110) and the second component segment (112) are additively printed such that at least a portion of the tongue (130) of the first component segment (110) is nested within the groove (132) defined by the second component segment (112). Segmented components having a tesla valve (250) formed therebetween are also provided.