Split Gas Turbine Case Assembly Using Additive Manufacturing
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Solution Overview
Problem
Current static engine structures for gas turbine engines, composed of tubular axial case segments, face challenges in manufacturing and assembly efficiency, requiring improved methods for constructing and connecting these components.
Innovation Solution
A manufacturing method involving additive manufacturing to form a split case structure from discrete case segments, which are monolithic and connected via sealed joints, allowing for a single-unit assembly of the rotating structure and reducing the complexity of traditional axial segment connections.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If traditional tubular axial case segments are used and connected by flange connections, then the static engine structure can be assembled, but the manufacturing and assembly complexity increases and efficiency decreases
Solution Approach 1:
The patent merges multiple discrete case segments into a single monolithic case structure formed by additive manufacturing. This eliminates the need for flange connections and multiple assembly steps, directly resolving the contradiction by combining what was previously separate components into one integrated structure, thereby improving manufacturing efficiency while reducing assembly complexity
Solution Approach 2:
The patent replaces traditional mechanical flange connection systems with an additive manufacturing process that creates a monolithic structure. This substitution eliminates mechanical fasteners, seals, and alignment requirements, directly addressing the contradiction by replacing a complex mechanical assembly system with a single manufacturing process
2Productivity
If discrete case segments are used, then assembly is possible, but the structural integrity and manufacturing efficiency are reduced
Solution Approach 1:
The patent combines discrete case segments into a single monolithic structure through additive manufacturing, which inherently improves both assembly efficiency (by eliminating assembly steps) and structural integrity (by removing joint interfaces). This single principle simultaneously addresses both aspects of the contradiction
Solution Approach 2:
The patent substitutes mechanical assembly with additive manufacturing, replacing the need for joining discrete segments with a process that creates a continuous, monolithic structure. This substitution improves productivity by eliminating assembly operations while enhancing strength by removing potential failure points at joints
3Ease of operation
If traditional axial segment connections are used, then the engine structure can be constructed, but the size constraints on the rotating assembly increase
Solution Approach 1:
The patent replaces traditional mechanical connection systems with additive manufacturing, creating a monolithic case structure with internal cavities that can accommodate rotating assemblies of larger dimensions. This substitution improves ease of operation by eliminating complex assembly constraints while increasing the available volume for rotating components
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 enables efficient assembly and enhances the structural integrity of the gas turbine engine by forming a single monolithic body of the static engine structure, improving manufacturing efficiency and reducing the size constraints on the rotating assembly.
Implementation Method 1
A manufacturing method is provided for additive manufacturing of a static engine structure of a gas turbine engine
Data Source
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AI summary
An assembly is provided for a gas turbine engine. This gas turbine engine assembly includes a split case structure. The split case structure includes a first wall, a second wall, a first case segment and a second case segment. The first wall extends axially along and circumferentially about an axial centerline. The second wall extends axially along and circumferentially about the axial centerline. The second wall is radially outboard of and axially overlaps the first wall. The first case segment is configured to form a first portion of the first wall and a first portion of the second wall. The second case segment is configured to form a second portion of the first wall and a second portion of the second wall. The second case segment is circumferentially adjacent and attached to the first case segment at a joint.