Staggered Weld Stubs for Flash Interference in Blisk Fabrication
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
In linear friction welding of bladed discs, flash expelled from weld joints often interferes with adjacent joints, requiring de-flashing after each weld and precise repositioning of the part-finished blisk, increasing costs and time.
Innovation Solution
The workpiece design features alternating first and second stub portions with offset weld joint planes, allowing flash from each weld to pass above or below neighboring flash, enabling all welds to be completed in a single pass without intermediate de-flashing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of substance
If linear friction welding is used to manufacture bladed discs, then material utilization is improved, but flash interference between adjacent joints increases
Solution Approach 1:
The patent introduces a radial dimension offset between alternating weld joints. Instead of all joints being coplanar, alternating joints are positioned at different radial heights, creating a three-dimensional staggered arrangement that allows flash to be expelled in different radial directions without interfering with adjacent joints.
Solution Approach 2:
The weld joint plane is segmented into multiple levels (first and second radial positions). By dividing the originally single-plane joint into staggered segments at different radial heights, the flash from each segment can be directed separately without clashing with flash from other segments.
2Object-affected harmful factors
If de-flashing is performed after each weld, then flash interference is eliminated, but fabrication time and cost increase
Solution Approach 1:
The offset configuration is built into the workpiece design before welding begins. This preliminary geometric arrangement prevents flash interference from occurring during the welding process itself, eliminating the need for subsequent de-flashing operations and associated downtime.
Solution Approach 2:
The staggered joint configuration enables continuous welding operations without interruption for de-flashing. The flash from each joint is naturally directed away from other joints, allowing the welding process to proceed continuously through all joints without breaking the productive action.
3Productivity
If the part-finished blisk is repositioned to complete remaining welds, then welding can be completed, but precision and cost increase
Solution Approach 1:
All weld joints are configured in a fixed staggered arrangement that allows them to be accessed and completed in a single continuous welding operation. This merges what would otherwise require multiple separate positioning operations into one unified process, eliminating the need for repositioning and its associated precision requirements.
4Object-affected harmful factors
If alternating aerofoil to rotor friction welds are completed before removing flash, then flash interference is avoided, but total fabrication time increases
Solution Approach 1:
By utilizing the radial dimension to offset alternating joints, the patent allows all joints to be welded simultaneously without flash interference. This eliminates the time loss associated with completing welds in alternating sequences and removes the need for intermediate de-flashing operations.
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 design reduces fabrication time and costs by allowing continuous welding without flash interference, making the process more efficient and convenient.
Implementation Method 1
material that is softened by heat generated by friction, pressure or an external heat source
Implementation Method 2
linear friction welding (LFW) to manufacture bladed discs
Data Source
AI summary
A workpiece for use with a flash producing welding process comprises a revolute body, a plurality of first attachment portions, a plurality of second attachment portions. The revolute body has an axis of rotation.Each of the first attachment portions has a first radially outer weld joint surface, and each of the second attachment portions has a second radially outer weld joint surface. The revolute body comprises a plurality of first and second stub portions, with each of the first stub portions having a first radially inner weld joint surface, and each of the second stub portions having a second radially inner weld joint surface.