Removable Anti-Wear Tip for Turbomachine Blades
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Solution Overview
Problem
Existing methods for installing anti-wear materials on turbomachine blade tips, such as 'Stelliting', are complex, prone to cracks and material voids, and require frequent repairs due to bi-material interfaces and difficulties in interfacing.
Innovation Solution
A removable anti-wear part with folded ends, designed to be attached to the blade tip edges, allowing for rapid and simple replacement, which can be made of anti-wear material and coated with high-hardness alloys like cobalt-based 'Stellite', and can be deformed for secure attachment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If anti-wear material is deposited by brazing or filling (Stelliting), then wear resistance of blade tip is improved, but manufacturing complexity increases and material defects (cracks, voids) occur
Solution Approach 1:
The anti-wear protection is segmented into a separate removable part rather than being integrated into the blade structure. This allows the anti-wear material to be applied as a standalone component that can be independently manufactured and replaced, simplifying the overall manufacturing process and eliminating bi-material interface issues.
Solution Approach 2:
The anti-wear material is extracted from the blade structure and implemented as a separate removable part. This extraction eliminates the complex brazing or filling operations required to integrate anti-wear material directly into the blade, while also removing the source of manufacturing defects associated with these processes.
2Reliability
If anti-wear material is applied by Stelliting, then wear resistance is improved, but material defects (cracks, voids) are generated at bi-material interface
Solution Approach 1:
The removable part is designed with localized anti-wear material application only at the tip edges where wear occurs, rather than requiring homogeneous material composition throughout the entire blade structure. This allows the blade body to maintain its original material properties while the tip receives enhanced wear protection.
Solution Approach 2:
The removable part can be manufactured as a single-material component or with uniform anti-wear material coating, eliminating the bi-material interface that causes cracks and voids. The homogeneous construction of the removable part itself, combined with its simple attachment mechanism, resolves the material stability issues.
3Ease of repair
If removable anti-wear part is used, then ease of repair is improved, but attachment mechanism complexity increases
Solution Approach 1:
The removable part incorporates deformable ends that can dynamically change shape during installation and removal. The ends are deformable to enable attachment by elastic deformation, allowing simple snap-fit or interference-fit installation without complex fastening mechanisms, while maintaining secure attachment during operation.
4Reliability
If traditional Stelliting is performed, then wear protection is achieved, but frequent repairs are required due to material wear and interface failures
Solution Approach 1:
The removable part is pre-equipped with anti-wear material during manufacturing, so that wear protection is already in place before the blade enters service. This preliminary application of anti-wear protection eliminates the need for complex field repairs and extends service life between maintenance intervals.
Solution Approach 2:
The removable part is designed as a consumable component that can be easily replaced when worn, rather than requiring repair of the integrated anti-wear material. This approach allows rapid replacement of the worn anti-wear part while recovering the main blade structure, significantly reducing total maintenance time and improving service life.
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 solution simplifies the 'Stelliting' process, reduces material waste, and enhances durability by providing a single-material, deformable anti-wear solution that can be easily replaced when worn, thereby improving wear resistance and reducing maintenance costs.
Implementation Method 1
The removable part can be deformable, so as to allow its attachment to the blade tip, preferably by elastic deformation.
Data Source
AI summary
An assembly includes: a movable blade for a turbomachine including a tip; and a removable part including an anti-wear material, configured to be attached removably to an edge of the tip to limit wear of the tip.