Rotating Machine Component With Composite Inner And Protective Outer Portions
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Solution Overview
Problem
Current gas turbine blade manufacturing techniques face limitations in operational temperatures, leading to reduced efficiency and increased structural complexity due to cooling requirements, which compromise performance and longevity.
Innovation Solution
A method involving a structural inner portion made of refractory metals or eutectic alloys with high tensile strength and creep resistance, combined with a protective outer portion having superior corrosion resistance, allowing for higher operational temperatures without the need for cooling systems, achieved through additive manufacturing and hot isostatic pressing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If cooling systems are added to turbine blades to enable higher operational temperatures, then temperature capability is improved, but device complexity and structural complexity increase
Solution Approach 1:
The patent applies composite materials by combining a nickel-based superalloy matrix with embedded ceramic particles (such as silicon carbide, aluminum oxide, or zirconium oxide). This composite structure enables the blade material itself to withstand higher temperatures without requiring complex cooling systems, as the ceramic particles provide thermal stability and structural reinforcement at elevated temperatures.
2Temperature
If cooling systems are added to turbine blades to enable higher operational temperatures, then temperature capability is improved, but manufacturing cost increases
Solution Approach 1:
The patent applies composite materials by combining a nickel-based superalloy matrix with embedded ceramic particles (such as silicon carbide, aluminum oxide, or zirconium oxide). This composite structure enables the blade material itself to withstand higher temperatures without requiring complex cooling systems, as the ceramic particles provide thermal stability and structural reinforcement at elevated temperatures.
3Ease of manufacture
If traditional nickel-based superalloys are used in turbine blades, then manufacturing is straightforward, but temperature capability is limited
Solution Approach 1:
The patent applies composite materials by combining a nickel-based superalloy matrix with embedded ceramic particles (such as silicon carbide, aluminum oxide, or zirconium oxide). This composite structure enables the blade material itself to withstand higher temperatures without requiring complex cooling systems, as the ceramic particles provide thermal stability and structural reinforcement at elevated temperatures.
4Use of energy by moving object
If operational temperatures are increased to improve gas turbine efficiency, then energy efficiency is improved, but material degradation and corrosion increase
Solution Approach 1:
The patent applies composite materials by combining a nickel-based superalloy matrix with embedded ceramic particles (such as silicon carbide, aluminum oxide, or zirconium oxide). This composite structure enables the blade material itself to withstand higher temperatures without requiring complex cooling systems, as the ceramic particles provide thermal stability and structural reinforcement at elevated temperatures.
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 thermo-structural resistance, extends component life, reduces production costs, and eliminates the need for cooling systems at current temperatures, thereby improving gas turbine efficiency.
Implementation Method 1
forming the inner portion (2) of the blade by additive manufacturing under computer control
Implementation Method 2
consolidating the deposited material by hot isostatic pressing
Data Source
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AI summary
A method for manufacturing a component (1) of a rotating machine comprises the steps of forming a structural inner portion (2) by additive manufacturing from a first material; covering the structural inner portion (2) with a protective outer portion (7) made of a second material; the first material has a melting point higher than a second material.