Pre-Applied Brazing Layer for Automated Turbine Component Joining
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Solution Overview
Problem
The manufacturing of gas turbine engine components through brazing operations is time-consuming and requires manual monitoring to prevent excess brazing alloy from flowing into critical areas, limiting automation and increasing costs.
Innovation Solution
A method involving a layered structure with a pre-applied brazing alloy layer on a base structure, which is secured to the turbine engine component, allowing for automated brazing operations by ensuring the right amount of brazing material is applied directly to the component, reducing the need for manual application and excess material.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If brazing alloy is applied externally to fill gaps during brazing operations, then gaps between cover plate and airfoil component are filled, but excess brazing alloy flows into hollow regions requiring extra steps and manual monitoring
Solution Approach 1:
The brazing alloy is pre-applied to the cover plate before the brazing operation, rather than being applied externally during the process. This preliminary action ensures the brazing alloy is already in position to fill gaps adequately while preventing excess from flowing into hollow regions, eliminating the need for manual monitoring during the brazing operation.
2Manufacturing precision
If brazing operations are performed with manual monitoring to prevent excess alloy, then manufacturing precision is maintained, but automation is limited and time increases
Solution Approach 1:
By pre-applying the brazing alloy to the cover plate before assembly, the need for manual monitoring during brazing is eliminated. This allows the brazing operation to be automated completely, significantly reducing manufacturing cycle time while maintaining precision control over brazing alloy application.
3Strength
If brazing alloy is applied to ensure adequate gap filling, then joint strength is improved, but excess material flows into critical areas requiring recycling or scrapping
Solution Approach 1:
The brazing alloy is pre-applied in controlled amounts to the cover plate before assembly. This preliminary positioning ensures adequate gap filling for strong joints while preventing excess alloy from flowing into hollow regions or critical areas, thereby eliminating the need to recycle or scrap airfoil components.
4Manufacturing precision
If multiple steps of applying and furnace treatment are repeated, then gap filling adequacy is ensured, but manufacturing time increases
Solution Approach 1:
The brazing alloy is pre-applied to the cover plate in a single step before assembly, eliminating the need for repeated application and furnace treatment cycles. This preliminary action ensures adequate gap filling is achieved in one brazing operation, significantly reducing total manufacturing time while maintaining gap filling adequacy.
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 reduces the time and complexity of brazing operations, enables automation, and minimizes the risk of excess brazing alloy, thereby enhancing manufacturing efficiency and reducing costs.
Implementation Method 1
heating, then putting the paste base structure onto the brazing layer
Implementation Method 2
a brazing alloy is applied externally to fill the gaps between the cover plate and the airfoil component via capillary action
Implementation Method 3
The brazing alloy is pre-applied to the base structure... allowing for automated brazing operations
Data Source
Figure 1~3
Figure 4~5
AI summary
A layered structure (26) comprises a base structure (28) having a major surface (32, 34), and a brazing layer (30a, 30b) secured to the major surface (32, 34) of the base structure (28), where the brazing layer (30a, 30b) is applied to the major surface (32, 34) prior to positioning the layered structure in contact with a turbine engine component.