Superalloy Rotor Component Internal Voids
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Solution Overview
Problem
Gas turbine engine rotor components, such as compressor impellers and turbine disks, face challenges with high operating temperatures, weight increase due to the use of nickel-based superalloys, and lack of internal cooling methods, leading to inefficiencies and increased manufacturing costs.
Innovation Solution
A method of forming rotationally mounted rotor components with internal voids using a mold and core insert, where a superalloy metal powder is hot-isostatic pressed around the core insert, and the core is subsequently removed to create voids within the component, providing both weight reduction and internal cooling passages.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If nickel-based superalloys are used to increase operating temperature capability, then temperature resistance is improved, but component weight increases
Solution Approach 1:
The patent applies porous materials by incorporating internal voids within the rotor component structure. These voids reduce the overall density and weight of the nickel-based superalloy component while maintaining the high-temperature capability of the material itself. The porous structure allows the component to operate at elevated temperatures (1300-1500°F) without the full weight penalty of solid superalloy construction.
Solution Approach 2:
The patent employs composite materials by combining nickel-based superalloy with internal void spaces to create a hybrid structure. This composite approach integrates the heat-resistant properties of superalloy with the weight-reduction benefits of voided geometry, achieving both high-temperature operation and reduced component mass.
2Weight of moving object
If internal voids are created to reduce weight, then component weight is reduced, but manufacturing complexity increases
Solution Approach 1:
The patent applies preliminary action by placing core inserts within the mold before filling with superalloy powder. These core inserts define the locations where voids will eventually form. By pre-positioning these cores, the complex task of creating internal voids is simplified into a straightforward molding operation, avoiding the need for complex post-processing or intricate mold designs.
Solution Approach 2:
The patent uses core inserts as intermediary objects that facilitate void creation. These temporary structures serve as placeholders during manufacturing, making the void-creation process simple and repeatable. After consolidation, the core inserts are removed (via extraction or dissolution), leaving the desired voids without requiring complex manufacturing steps.
3Ease of manufacture
If traditional manufacturing methods are used, then manufacturing process is simple, but internal cooling passages cannot be provided
Solution Approach 1:
The patent applies universality by designing the voids to serve multiple functions simultaneously. The same internal void spaces that reduce component weight also serve as cooling passages for thermal management. This multi-functional design allows a single manufacturing approach (powder consolidation with core removal) to achieve both weight reduction and cooling capability, without requiring separate complex cooling system integration.
4Strength
If nickel-based superalloys replace titanium components, then high temperature strength is improved, but manufacturing cost increases
Solution Approach 1:
The patent applies parameter changes by transitioning from solid to porous superalloy structure. This parameter change (introducing voids) reduces the amount of expensive nickel-based superalloy material required, thereby lowering manufacturing costs while preserving the necessary high-temperature strength through strategic void placement that avoids critical stress zones.
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 method enables the creation of lighter, more efficient rotor components capable of operating at higher temperatures with internal cooling, thereby improving the operational efficiency of gas turbine engines while reducing manufacturing costs.
Implementation Method 1
hot-isostatic pressing the mold and powder to consolidate the powder about the core insert and form a superalloy structure
Implementation Method 2
coating the core insert with a diffusion barrier
Data Source
AI summary
A rotor component assembly including at least one void space formed therein that provides for reduction in weight of the component and/or cooling of the component during operation. The rotor component is formed by positioning a coated mild steel insert within a mold having an internal cross-section substantially the same in dimensions as the final rotor component. The mold is filled with a superalloy metal powder and undergoes hot-isostatic pressing to consolidate the powder about the coated core insert and form a superalloy structure. The mold is removed from about the superalloy structure and the core insert is removed from within the superalloy structure, thereby defining the at least one internal void within the rotor component.