Superalloy Turbine Casing Gradient Manufacturing
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Solution Overview
Problem
The existing methods for manufacturing turbine casings require the use of high-performance superalloys for both the main and secondary portions, which are expensive and difficult to work with, especially for secondary portions subjected to high thermomechanical stresses, necessitating a more cost-effective and easier method to achieve parts with different superalloy materials.
Innovation Solution
A direct metal deposition method is used to create a composition gradient by depositing a second superalloy portion on a first superalloy portion, with each layer having a specific weight percentage of the superalloys, allowing for a single-piece part with improved thermomechanical compatibility and reduced manufacturing costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If high-performance superalloy is used for the entire turbine casing to withstand high thermomechanical stresses in secondary portions, then the mechanical strength and temperature resistance are improved, but the manufacturing cost and difficulty increase significantly
Solution Approach 1:
The patent applies different superalloy materials to different portions of the turbine casing based on their specific functional requirements. The secondary portions (attachment portions, sealing portions, cooling portions) that are subjected to high thermomechanical stresses are made of a first superalloy with superior high-temperature strength, while the main annular portion is made of a second superalloy that is easier and less expensive to manufacture. This local differentiation of material quality resolves the contradiction by providing high performance only where needed rather than uniformly across the entire component.
Solution Approach 2:
The turbine casing is segmented into distinct portions (main annular portion and secondary portions) that are manufactured separately using different superalloy materials and then joined together. This segmentation allows each portion to be optimized independently - the secondary portions use high-performance but difficult-to-manufacture superalloy, while the main portion uses a more economical superalloy, thereby resolving the contradiction between overall strength requirements and manufacturing ease.
2Stability of the object's composition
If the same superalloy is used for both main and secondary portions to ensure uniform material properties, then the thermomechanical compatibility is improved, but the manufacturing cost increases
Solution Approach 1:
The patent implements local quality by selecting superalloy materials based on the specific thermomechanical conditions of each portion. The first superalloy for secondary portions is selected for its superior high-temperature strength and creep resistance, while the second superalloy for the main portion balances performance with manufacturability and cost. This localized material selection achieves adequate thermomechanical compatibility for each specific application while optimizing overall manufacturing cost.
Solution Approach 2:
The patent changes the material parameters (superalloy composition and properties) according to the specific requirements of different portions. By adjusting the alloy composition parameters - using a first superalloy with higher nickel content and specific alloying elements for secondary portions, and a second superalloy with different composition for the main portion - the patent achieves cost-effective thermomechanical compatibility tailored to each portion's functional demands.
3Temperature
If high-performance superalloy is used for secondary portions to withstand high temperatures, then the temperature resistance is improved, but the ease of working during manufacturing deteriorates
Solution Approach 1:
The patent applies the first superalloy with superior temperature resistance specifically to the secondary portions that are exposed to high thermomechanical stresses and temperatures, while using the second superalloy for the main portion where such extreme conditions are not present. This localized application of high-temperature resistant material improves temperature resistance where needed while avoiding the manufacturing difficulties associated with working this difficult-to-process superalloy throughout the entire component.
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 production of a single-piece part with different superalloys, utilizing a more expensive high-performance superalloy for high-stress areas and a less expensive alloy for other areas, while enhancing thermomechanical compatibility and simplifying the manufacturing process.
Implementation Method 1
depositing the second portion on a surface of the first portion by a direct metal deposition method (DMD), deposition of the second portion comprising at least depositing a first layer on said surface, then depositing a second layer on the first layer
Implementation Method 2
a deposition head has a high energy beam (e.g. an electron beam or a laser beam) that encounters a metal wire or a focused stream of metal powder so as to melt the metal and deposit drops of metal as melted in this way
Implementation Method 3
a deposition head has a high energy beam (e.g. an electron beam or a laser beam) that encounters a metal wire or a focused stream of metal powder so as to melt the metal
Data Source
AI summary
A method of manufacturing a superalloy part including a first portion including a majority by weight of a first superalloy and a second portion including a majority by weight of a second superalloy, the second portion extending from the first portion, the method including depositing the second portion on the first portion by a direct metal deposition method, deposition of the second portion including depositing a first layer, then depositing a second layer on the first layer, the first layer including the first and second superalloys, the first layer presenting a content by weight of the first superalloy that is strictly greater than that content by weight of the second layer and strictly less than that content by weight of the first portion, the second layer presenting a content by weight of the second superalloy that is strictly greater than that content by weight of the first layer.