Rounded Stub Geometry for Orbital Welding of Turbomachine Blades
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing orbital friction welding methods for turbomachine blades result in structural defects and material health issues due to inadequate stub design, leading to contaminants and non-homogeneous welds.
Innovation Solution
A method for sizing the junction section between a blade and a stub with rounded contours at the ends, each with an average radius of at least twice the eccentric, ensuring optimal contact surface and material homogeneity during welding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional stub design is used for orbital friction welding, then welding process can be completed, but structural defects and material health defects occur in the weld junction
Solution Approach 1:
The stub is designed with non-uniform geometry featuring a rounded contour at the welding interface with a specific radius of curvature (R ≥ 2mm). This local geometric modification at the contact surface improves material flow and thermal distribution during orbital friction welding, eliminating weld defects while maintaining simple overall stub structure for ease of manufacture
Solution Approach 2:
The invention specifies precise geometric parameters for the stub welding interface, particularly the radius of curvature (R ≥ 2mm) and the rounded contour shape. These parameter changes optimize the friction welding process by ensuring homogeneous heating and proper material mixing, thereby preventing structural defects and contaminants in the weld junction
2Productivity
If orbital friction welding is performed with standard stub geometry, then welding speed is maintained, but thermal homogeneity and material mixing are insufficient
Solution Approach 1:
The stub welding interface is designed with a rounded contour and specific radius of curvature (R ≥ 2mm) instead of sharp edges or flat surfaces. This curvature ensures continuous contact during orbital motion, maintaining constant friction heat generation and homogeneous temperature distribution throughout the welding process, achieving both high productivity and thermal homogeneity
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 method achieves a robust and contaminant-free weld with improved structural integrity by maintaining consistent material mixing and thermal homogeneity, reducing the risk of structural defects and contaminants.
Implementation Method 1
orbital friction welding is a welding process in which the parts to be assembled are brought into contact under force and welded by a circular movement generally defined by an eccentric, and accompanied by a uniform tangential speed, so as to generate a friction and homogeneous heating at the level of a weld junction between the two parts
Implementation Method 2
a forging force is exerted on the blade against the rotor in order to finalize the weld
Data Source
AI summary
A method for sizing a section of a junction by orbital friction welding with an eccentric e, between a blade and a stub of a bladed disk for a turbomachine. The sized section has a rounded contour at one or two ends of said section along a chord of the blades, each corresponding to a leading edge or a trailing edge of said blades, said rounded contour(s) having over a sector of at least 120° an average radius of at least twice the eccentric e.