3D Printed Continuous-Flow Engine Components Using Vibration
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Solution Overview
Problem
Existing 3D printing methods for continuous flow engine components, such as gas turbines and steam turbines, struggle to optimize manufacturing for high reliability and mechanical stability while reducing effort and cost, posing risks to energy production and safety.
Innovation Solution
A method involving vibration treatment at predetermined frequencies to relieve internal stresses in 3D printed components, potentially combined with heating, and a computer program product to execute this method, along with a powder removal device that applies vibrations to reduce stress and remove powder material.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional heat treatment methods are used to relieve stress in 3D printed components, then stress relief is achieved, but treatment time becomes excessively long (hours to weeks)
Solution Approach 1:
The patent applies mechanical vibration at specific frequencies to relieve internal stresses in 3D printed components. The vibration treatment causes stress relaxation through mechanical energy input, achieving stress relief in minutes to hours rather than the days to weeks required by traditional heat treatment methods. This directly resolves the contradiction by providing effective stress relief with dramatically reduced treatment time.
Solution Approach 2:
The patent changes the physical state and parameters of the component by applying controlled vibration frequencies and amplitudes. By adjusting vibration parameters (frequency, amplitude, duration) rather than relying on thermal parameters, the process achieves stress relief much faster than conventional heat treatment, transforming a time-consuming thermal process into a rapid mechanical process.
2Ease of manufacture
If 3D printing is used to manufacture continuous flow engine components, then manufacturing flexibility and complexity reduction are improved, but internal stresses are introduced that compromise mechanical stability
Solution Approach 1:
The patent applies preliminary vibration treatment to the 3D printed component immediately after manufacturing to relieve internal stresses before the component is put into service. This preliminary action prevents stress-related failures later in the component's operational life, maintaining mechanical stability while preserving the manufacturing flexibility benefits of 3D printing.
Solution Approach 2:
By applying mechanical vibration as a post-processing treatment, the patent addresses the stress instability issue inherent in 3D printed components. The vibration treatment relaxes internal stresses without requiring changes to the 3D printing process itself, thus maintaining manufacturing flexibility while improving mechanical stability.
3Loss of time
If vibration treatment is applied to relieve stress, then treatment time is significantly reduced, but additional equipment and process complexity are required
Solution Approach 1:
The patent designs the vibration treatment system to serve multiple functions: stress relief, powder removal, and potential surface treatment. By making the equipment multi-functional, the patent reduces the need for separate specialized devices, thereby limiting the increase in device complexity while achieving rapid stress relief.
Solution Approach 2:
The vibration treatment process can be integrated into existing manufacturing workflows where the same equipment that handles other operations can also perform stress relief. The system serves itself by using the vibration mechanism for multiple purposes, reducing the need for additional dedicated equipment and minimizing the increase in overall device 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
Significantly reduces stress in components, shortens treatment time, and enhances mechanical stability, allowing for safer and more reliable operation under demanding conditions, while minimizing time and effort.
Implementation Method 1
vibrating the continuous flow engine component at a predetermined frequency to remove the internal stresses from the 3D printed continuous flow engine component
Implementation Method 2
heating the component to a specified temperature to relieve it from such stress
Data Source
AI summary
The present invention refers to an improved method of relieving a 3D printed continuous flow engine of stress. Furthermore, the present invention refers to a 3D printed continuous flow engine component relieved from stress by such method. Furthermore, the present invention refers to a computer program product causing a computing entity to execute such method. Furthermore, the present invention refers to a powder removal device to be utilized in such method.