Controlled Recrystallized Surface Layer for Turbomachine Components
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Solution Overview
Problem
Conventional methods for forming recrystallized surface layers on turbomachine components, such as shot-blasting, introduce uncontrolled plastic deformation, leading to irregular and unpredictable recrystallization depths, which affect the quality and uniformity of the surface layer.
Innovation Solution
The method involves controlled plastic deformation techniques like shot-peening, laser shot-peening, ultrasonic peening, explosion forming, or burnishing, combined with heat treatment and hot isostatic pressing, to achieve a predetermined recrystallized layer with a specific depth and grain size, ensuring uniformity and desired material characteristics.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If conventional shot-blasting methods are used to remove shell material and improve surface finish, then surface finish is improved, but plastic deformation depth becomes uncontrolled and irregular
Solution Approach 1:
The patent applies parameter changes by controlling the parameters of the plastic deformation process (such as shot size, shot velocity, shot angle, and number of shots) to achieve a predetermined depth of plastic deformation. This transforms the uncontrolled conventional shot-blasting into a controlled process where the depth of the affected layer can be precisely adjusted to create a uniform recrystallized layer at the surface.
2Ease of manufacture
If uncontrolled plastic deformation is introduced through blasting, then surface cleaning is achieved, but recrystallization depth becomes uncontrolled and irregular
Solution Approach 1:
The patent applies preliminary action by first controlling the plastic deformation process to create a specific depth of deformation before heat treatment. This preliminary controlled deformation ensures that when subsequent heat treatment is applied, the recrystallization occurs at a predetermined depth, resulting in a uniform and controlled recrystallized layer rather than irregular deep recrystallization.
3Ease of manufacture
If conventional blasting methods are used, then shell material and oxides are removed, but the quality and uniformity of the surface layer deteriorates
Solution Approach 1:
The patent applies local quality by concentrating the plastic deformation and subsequent recrystallization effects at a specific surface layer with controlled depth, while leaving the bulk material properties unchanged. This creates a localized uniform recrystallized layer at the surface that improves quality and uniformity, distinct from the unaffected interior material.
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 approach enhances the high cycle fatigue life and material properties of turbomachine components by creating a uniform recrystallized layer with a controlled depth, improving both the quality and consistency of the surface layer compared to uncontrolled methods.
Implementation Method 1
a formed material includes a composition including a non-recrystallized portion that is not processed to deliberately affect the crystal structure and/or grain size thereof. The formed material also includes a processed or recrystallized layer of the composition with a predetermined depth
Implementation Method 2
Modification of the surface composition can be followed by a phase transformation
Data Source
Figure 1~2
AI summary
A formed material can include a composition having a non-recrystallized portion and a recrystallized layer of the composition having predetermined depth, the recrystallized layer forming at least part of a surface of the composition that overlays the non-recrystallized portion. A method of forming a material having an at least partially recrystallized layer can include forming a composition into a predetermined shape having a surface, wherein the forming leaves the surface of the composition in a non-recrystallized state. The method can also include determining a desired depth of at least a portion of a recrystallized layer at the surface and recrystallizing at least a portion of the surface of the composition to form the recrystallized layer to the desired depth.