Additively Manufactured Plastic Rotor Shrouds with CTE-Matched Plating
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Solution Overview
Problem
Poor adhesion between metal plating and plastic substrate in metal-plated components leads to reduced durability, particularly in varying temperature environments, which is a limitation in gas turbine engine applications.
Innovation Solution
A metal-plated plastic rotor shroud with a fiber-reinforced plastic substrate designed to control thermal expansion by embedding fibers within a plastic matrix, matching the coefficient of thermal expansion (CTE) of the metal plating to enhance adhesion and durability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If metal plating is applied to plastic substrate to increase strength and abrasion resistance, then the strength and durability of the component is improved, but the adhesion between metal plating and plastic substrate deteriorates, leading to separation at variable temperatures
Solution Approach 1:
The patent applies parameter changes by modifying the thermal expansion characteristics of the plastic substrate through fiber reinforcement. By selecting fibers with specific CTE values and controlling their orientation and concentration, the substrate's thermal expansion behavior is adjusted to match the metal plating, thereby preventing adhesion failure at variable temperatures while maintaining the strength benefits of metal plating
Solution Approach 2:
The patent uses composite materials by combining plastic matrix with fiber reinforcements to create a substrate that has tailored thermal expansion properties. This composite structure allows the plastic substrate to exhibit thermal expansion behavior that matches the metal plating, ensuring durable adhesion while maintaining the lightweight and corrosion-resistant advantages of plastic
2Reliability
If fiber reinforcement is added to plastic substrate to control thermal expansion, then the adhesion and durability are improved, but the manufacturing complexity increases
Solution Approach 1:
The patent applies preliminary action by incorporating fiber reinforcement into the plastic substrate during the additive manufacturing process itself, rather than adding it as a separate post-processing step. The fibers are included in the filament or material feedstock and are deposited along with the plastic matrix, pre-establishing the reinforced composite structure before metal plating is applied
Solution Approach 2:
The patent merges multiple functions into a single additive manufacturing process: producing the plastic substrate, incorporating fiber reinforcement, and creating the composite structure all in one operation. This integration eliminates the need for separate reinforcement installation steps and simplifies the overall manufacturing workflow while achieving the desired thermal expansion control
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
The solution provides improved adhesion and durability by controlling thermal expansion, reducing weight, and enhancing the longevity and efficiency of rotor shrouds in turbomachines.
Implementation Method 1
embedding fibers within a plastic matrix, matching the coefficient of thermal expansion (CTE) of the metal plating to enhance adhesion
Data Source
Figure 1~2
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AI summary
In one aspect, a rotor shroud for a rotary machine includes a disk portion (218) extending along and oriented about a central axis of the rotary machine, a transition portion (220) extending from the disk portion, and a flared portion (222) extending axially from the transition portion. The disk portion, the transition portion, and the flared portion include a plastic substrate (12, 32) and metal plating (24) disposed on at least apportion of an outer surface of the plastic substrate. The plastic substrate has a matrix material (14, 34) and fibers (16, 36) embedded in the matrix material. The fibers have a first coefficient of thermal expansion. The metal plating has a second coefficient of thermal expansion. The fibers are selected such that a bulk coefficient of thermal expansion of the plastic substrate at the outer surface of the plastic substrate substantially matches the second coefficient of thermal expansion of the metal plating.