Refractory Metal Airfoil Core Variable Thickness Additive Manufacturing
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Solution Overview
Problem
Current airfoil manufacturing techniques for gas turbine engines are limited by fragile core structures that require painstaking assembly and often result in scrapped cores due to abrupt transitions and fragile core elements, which restrict cooling configurations and material uniformity.
Innovation Solution
A refractory metal core with a variable thickness, constructed using additive manufacturing processes such as direct metal laser sintering, allowing for a unitary body with uniform material properties and tapered cooling passages, eliminating the need for multiple core elements and assembly, and enabling a robust core with smooth transitions and adherent coatings.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If traditional core assembly methods are used with multiple elements glued together, then cooling configurations can be formed, but the core becomes fragile and assembly is complex resulting in scrapped cores
Solution Approach 1:
The patent merges multiple separate core elements into a single integrated core structure that can be directly inserted into the mold. This unified core provides the necessary cooling configurations through its internal geometry rather than through assembly of multiple pieces, eliminating the fragility and assembly complexity associated with traditional multi-element cores while maintaining the required cooling functionality
Solution Approach 2:
The core is designed with segmented or modular features that allow for complex cooling passages and configurations within a single monolithic structure. The internal geometry is divided into functional zones for different cooling requirements, but these are formed as integral parts of one piece rather than separate elements requiring assembly
2Adaptability or versatility
If traditional core assembly methods are used with multiple elements, then cooling features can be created, but assembly complexity increases and time is lost
Solution Approach 1:
The patent combines multiple core elements into a single integrated core that provides all necessary cooling features through its internal geometry. This eliminates the painstaking assembly process of gluing multiple elements together, significantly reducing assembly time and increasing productivity while maintaining the complex cooling configurations required for gas turbine engine airfoils
3Ease of manufacture
If abrupt transitions are used in core elements, then manufacturing is simplified, but the core becomes fragile and transitions are not smooth
Solution Approach 1:
The patent incorporates smooth transitions and curved geometries in the core design, particularly in areas where thickness changes occur. Instead of abrupt transitions that create stress concentrations and fragility, the core uses radiused edges and gradual thickness variations that maintain structural integrity while still being manufacturable. This approach balances ease of manufacture with improved core strength and reliability
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 enables the production of airfoils with enhanced cooling features and improved structural integrity, reducing material waste and assembly complexities, while allowing for more flexible cooling configurations and uniform material properties throughout the core.
Implementation Method 1
depositing multiple layers of powdered metal onto one another, joining the layers to one another with reference to CAD data relating to a particular cross-section of a refractory metal core
Implementation Method 2
Airfoils, particularly those used in a hot section of a gas turbine engine, incorporate internal cooling features
Data Source
Figure 1
Figure 2A~2B
Figure 3A~3D
AI summary
A core (340) for an airfoil (26; 226; 326) includes a refractory metal structure having a variable thickness. An airfoil (26; 226; 326) includes a body having leading and trailing edges (30, 32) joined by spaced apart pressure and suction sides (34, 36) to provide an exterior airfoil surface (38; 360) defined by a perimeter wall (76). An interior wall (78) is arranged interiorly and adjacent to the perimeter wall (76) to provide a cooling passage (253; 66, 68, 70) there between. A cooling passage (253; 66, 68, 70) with first and second portions (62, 64) is tapered and respectively has first and second thicknesses (242, 244). The first thickness (242) is greater than the second thickness (244), and the second thickness (244) is less than 0.060 inch (1.52 mm). A method of manufacturing a refractory metal core (340) includes depositing multiple layers of powdered metal onto one another, joining the layers to one another with reference to CAD data relating to a particular cross-section of a refractory metal core (340), and producing the core (340) having a variable thickness.