Integral Stator Vane Weld Shield Additive Manufacturing
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Solution Overview
Problem
Gas turbine engine stator vane rings often have low yields, leading to many parts being scrapped, and the replacement process for damaged vanes is costly and involves additional operations such as removing weld spatter.
Innovation Solution
The development of a stator vane for gas turbine engines made using powder bed fusion additive manufacturing, which includes a vane segment, inner and outer shroud segments, a support structure, and a weld shield integrally formed during a single continuous process. This design allows for efficient replacement of damaged vanes by minimizing the need for additional operations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If traditional casting methods or additive manufacturing methods are used to make stator vane rings, then the parts can be produced, but the yields are low resulting in many parts being scrapped
Solution Approach 1:
The weld shield is pre-formed as an integral part of the stator vane during additive manufacturing, positioned to protect the suction side during subsequent welding operations. This preliminary preparation eliminates the need for separate shield installation and prevents weld spatter contamination before it occurs.
Solution Approach 2:
The weld shield is designed as a temporary protective element that is removed after serving its purpose during welding operations. This disposable approach is more economical than creating complex removable shielding systems or risking damage to expensive vane surfaces.
2Ease of repair
If the replacement process for damaged vanes involves traditional methods, then damaged vanes can be replaced, but additional operations such as removing weld spatter are required which increases cost and complexity
Solution Approach 1:
The weld shield acts as an intermediary protective barrier between the welding process and the vane suction side. It intercepts weld spatter and protects the critical aerodynamic surface, eliminating the need for post-weld cleaning operations.
Solution Approach 2:
The weld shield provides preliminary protection against weld spatter contamination before the harmful effect occurs. By positioning the shield during the additive manufacturing process, it prevents spatter adhesion to the suction side, making removal operations unnecessary.
3Ease of manufacture
If a weld shield is added to protect the suction side during welding, then weld spatter removal is eliminated, but the device complexity increases
Solution Approach 1:
The weld shield is merged with the stator vane structure by forming it as an integral part during additive manufacturing. This combining of functions (structural support + weld protection) into a single monolithic component eliminates the need for separate shield assemblies, fasteners, and alignment mechanisms.
Solution Approach 2:
The integrated weld shield serves multiple functions: it provides structural support as part of the vane, protects the suction side from weld spatter, and maintains aerodynamic integrity. This multi-functionality reduces the need for additional specialized 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
The proposed solution enhances the efficiency and cost-effectiveness of replacing damaged stator vanes by reducing scrap rates and eliminating the need for post-weld spatter removal, thereby improving the overall yield and reducing operational costs.
Implementation Method 1
made using powder bed fusion additive manufacturing
Implementation Method 2
The laser selectively melts regions of the powder bed to form a cross-section of the object, and the build plate is lowered and a new layer of powder is spread over the build plate. This process is repeated until the entire object is formed.
Data Source
AI summary
A stator vane for a gas turbine engine combustor has a vane segment that includes a vane having a leading edge, a trailing edge, a suction side, a pressure side, a vane inner base, and a vane outer base, an inner shroud segment attached to the vane at the vane inner base, and an outer shroud segment attached to the vane at the vane outer base. The stator vane further includes a support structure attached to the vane at a vane trailing edge, and a first weld shield attached to the support structure by a first connector. The first weld shield is positioned over and spaced away from the suction side. The vane, inner shroud segment, outer shroud segment, support structure, and first weld shield are integrally formed during a single, continuous additive manufacturing process.