Thermally Deformable Component With Tailored Expansion Coefficients

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Solution Overview

Problem

Components exposed to high thermal loads experience deformations due to temperature gradients, which existing technologies fail to adequately mitigate, leading to geometrical inaccuracies and stress issues.

Innovation Solution

A method involving the selective use of metallic materials with tailored thermal expansion coefficients, deposited via generative laser processes, to create components with reduced deformations, where the ratio of linear expansion coefficients and thermal conductivities are strategically matched across different areas, allowing for complex geometries and efficient cooling structures.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If a single metallic material is used for the entire component, then the manufacturing process is simple, but the component experiences excessive deformations due to temperature gradients

Engineering Contradiction:

Improvegeometrical accuracyVSAvoidmaterial composition

Core Design Contradiction:

Manufacturing precisionVSDevice complexity

Solution Approach 1:

The component is divided into multiple areas with different metallic materials, each having different linear expansion coefficients. This segmentation allows each area to respond differently to thermal loads, compensating for deformations and maintaining geometrical accuracy under temperature gradients.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Different areas of the component are assigned different metallic materials with specific properties tailored to local thermal conditions. Areas experiencing higher temperatures or greater thermal gradients use materials with appropriate expansion coefficients to minimize deformation, while other areas use materials optimized for their specific conditions.

Inventive Principle:

Principle #3Local quality

2Manufacturing precision

If multiple metallic materials with different expansion coefficients are used, then deformation is reduced, but the manufacturing process becomes more complex

Engineering Contradiction:

Improvedeformation controlVSAvoidmanufacturing process

Core Design Contradiction:

Manufacturing precisionVSEase of manufacture

Solution Approach 1:

The linear expansion coefficient is used as a key parameter to select and arrange different metallic materials in specific sequences. By carefully selecting materials whose expansion coefficients satisfy the relationship α1/α2 ≥ 0.5, the component achieves deformation control while maintaining manufacturability through systematic material selection rather than arbitrary complexity.

Inventive Principle:

Principle #35Parameter changes

3Reliability

If expensive heat-resistant materials are used throughout the component, then high temperature resistance is achieved, but manufacturing cost increases

Engineering Contradiction:

Improvethermal load resistanceVSAvoidmaterial cost

Core Design Contradiction:

ReliabilityVSQuantity of substance

Solution Approach 1:

Expensive heat-resistant materials are applied only in specific areas where high temperature resistance is critically needed, while other areas use more cost-effective materials. This localized material assignment maintains the component's ability to withstand thermal loads while significantly reducing overall material costs.

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The component uses a composite structure with multiple metallic materials, combining expensive heat-resistant alloys in critical areas with more economical materials in less demanding areas. This composite approach achieves the required thermal performance while optimizing material cost efficiency.

Inventive Principle:

Principle #40Composite materials

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 effectively minimizes deformations and enhances the geometrical accuracy of components under high thermal loads, enabling the use of cost-effective materials and improving cooling efficiency, while maintaining mechanical properties through heat treatment and hot isostatic pressing.

Implementation Method 1

at least one of the metallic materials is deposited by a generative laser process

Methodology Applied

Scientific EffectLaser melting: Melting

Implementation Method 2

at least one of the metallic materials is deposited by a generative laser process

Methodology Applied

Scientific EffectLaser deposition: Deposition (physical)

Implementation Method 3

the following applies for the ratio of the linear expansion α1 of the first metallic material and of the linear expansion coefficient α2 of the second metallic material

Methodology Applied

Scientific EffectThermal expansion: Thermal Expansion

Data Source

PatentUS9587317B2Method for the manufacture of a component for high thermal loads, a component producible by this method and an aircraft engine provided with the component

Publication Date: 2017.03.07 ROLLS ROYCE DEUT LTD & CO KG

AI summary

A method for manufacturing a thermally deformable component for high thermal loads, includes: providing a first area of the component with a first metallic material by a generative laser process, or making the first area of the first metallic material; providing a second area of the component with a second metallic material by a generative laser process, or making the second area of the second metallic material; where at least one of the metallic materials is deposited by the generative laser process, and a ratio of a linear expansion coefficient α1 of the first metallic material and of a linear expansion coefficient α2 of the second metallic material is as:α2⁡(T2)α1⁡(T1)=x⁢T1-T0T2-T0,where x=0.5 to 1; T1=mean operating temperature on a hot side; T0=reference temperature; T2=mean operating temperature on a cold side.