Single-Piece Gas Turbine Vane Array with Deformable Baffles
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Solution Overview
Problem
Existing vane arrays for gas turbine engines with mechanical interfaces increase engine weight and complicate assembly, while traditional manufacturing methods are inefficient and costly.
Innovation Solution
A single-piece annular vane array with integrated mounting features and deformable baffles, manufactured via additive layer manufacturing, which reduces interfaces and improves tolerancing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If multiple sub-structures joined by mechanical interfaces are used to form the vane array, then the structural complexity and ability to accommodate thermal stresses improve, but the engine weight increases and assembly ease deteriorates
Solution Approach 1:
The patent merges multiple sub-structures (mounting features, stator vanes, and baffles) into a single integrated vane array component. This consolidation eliminates the need for separate mechanical joints while maintaining the structural integrity and thermal stress accommodation capabilities through continuous material geometry, thereby reducing overall weight.
Solution Approach 2:
The patent applies local quality by incorporating deformable baffles at specific locations within the vane array to accommodate thermal stresses. Rather than making the entire structure complex, only the baffle portions are designed with deformability, allowing thermal expansion while keeping other regions optimized for strength and weight.
2Strength
If multiple sub-structures joined by mechanical interfaces are used to form the vane array, then the structural complexity and ability to accommodate thermal stresses improve, but the assembly ease deteriorates
Solution Approach 1:
By combining multiple components into a single integrated vane array, the patent eliminates the need for complex assembly procedures involving multiple mechanical interfaces. The entire structure can be installed as one unit, dramatically simplifying the assembly process while maintaining thermal stress accommodation through the integrated deformable baffle design.
3Weight of moving object
If a single-piece structure is used for the vane array, then the engine weight decreases and assembly ease improves, but the manufacturing precision and tolerancing worsen
Solution Approach 1:
The patent employs additive layer manufacturing to produce the single-piece vane array, representing a fundamental change in the manufacturing parameter from traditional subtractive or assembly-based methods. This manufacturing technique enables complex geometries with integrated deformable baffles to be produced directly, achieving both weight reduction and adequate manufacturing precision through digital fabrication control.
4Manufacturing precision
If traditional manufacturing methods are used for the vane array, then the manufacturing precision may be maintained, but the productivity decreases and cost increases
Solution Approach 1:
The patent transitions from traditional manufacturing parameters (subtractive machining, multiple assembly operations) to additive layer manufacturing parameters. This parameter change enables direct fabrication of complex single-piece structures, significantly improving productivity by eliminating multiple manufacturing steps while maintaining manufacturing precision through digital model control and layer-by-layer material deposition.
Data Source
AI summary
A single-piece annular vane array for a gas turbine engine. The single-piece annular vane array comprises at least one mounting feature, a ring of stator vanes, and at least one baffle. The at least one baffle is attached at a first radial location to the ring of stator vanes, and is attached at a second radial location to the at least one mounting feature. The at least one baffle is deformable.