Turbomachine Tip Member Airfoil Cross-Section Coupling

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Solution Overview

Problem

Conventional manufacturing techniques for turbomachine components, including both cast metal and additive manufacturing, fail to adequately account for the mechanical coupling of differently manufactured parts, leading to compatibility issues between cast metal and additively manufactured components.

Innovation Solution

A tip member with an airfoil cross-section and an opening for receiving a post is designed to be coupled with a blade structure, allowing for metallurgical bonding to form a turbomachine component, enabling mechanical coupling of cast metal blade structures with additively manufactured tip members.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If conventional manufacturing techniques (casting or additive manufacturing) are used to produce turbomachine components, then manufacturing scalability and speed are improved, but compatibility and mechanical coupling between differently manufactured parts deteriorate

Engineering Contradiction:

Improvemanufacturing speedVSAvoidcomponent compatibility

Core Design Contradiction:

ProductivityVSReliability

Solution Approach 1:

The tip member is divided into distinct functional zones: a body portion with airfoil cross-section for aerodynamic function, and an integrated opening structure for mechanical coupling. This segmentation allows each zone to be optimized for its specific function while ensuring compatibility between cast and additively manufactured components

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The opening in the tip member serves as an intermediary feature that receives a post from the blade structure, enabling mechanical coupling between components manufactured by different processes. This intermediary element bridges the compatibility gap between conventional and additive manufacturing techniques

Inventive Principle:

Principle #24Intermediary (Mediator)

2Adaptability or versatility

If tip member includes an opening for receiving a post, then mechanical coupling capability is improved, but structural complexity increases

Engineering Contradiction:

Improvemechanical coupling capabilityVSAvoidtip member structure

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The opening for mechanical coupling is merged directly into the body of the tip member during additive manufacturing, rather than being added as a separate component. This integration reduces overall assembly complexity while maintaining coupling capability

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The tip member design incorporates multiple functions within a single component: the body provides aerodynamic function with its airfoil cross-section, while the integrated opening provides mechanical coupling function. This multi-functionality reduces the need for additional separate components

Inventive Principle:

Principle #6Universality (Multi-functionality)

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 solution facilitates the formation of a strong, efficient turbomachine component by creating a single airfoil profile and allowing for metallurgical bonding between cast metal and laser-sintered materials, enhancing mechanical connection and versatility in component design and repair.

Implementation Method 1

The melting may be performed by a high power melting beam, such as a 100 Watt ytterbium laser, to fully weld (melt) the metal powder to form a solid metal

Methodology Applied

Scientific EffectLaser melting: Laser Beam Welding

Implementation Method 2

In metal powder additive manufacturing techniques, such as direct metal laser melting (DMLM) (also referred to as selective laser melting (SLM)), metal powder layers are sequentially melted together to form the component

Methodology Applied

Scientific EffectSelective laser melting: Selective Laser Sintering

Data Source

PatentUS10519777B2Tip member for blade structure and related method to form turbomachine component

Publication Date: 2019.12.31 GE INFRASTRUCTURE TECH LLC

AI summary

The disclosure relates to a tip member configured to be coupled to a blade structure for a turbomachine. A body of the tip member includes: a first surface configured to engage a radially outboard end of the blade structure, a second surface positioned opposite the first surface, and at least one perimeter sidewall positioned between the first and second surfaces, wherein the at least one perimeter sidewall has an airfoil cross-section; and an opening passing through the body from the first surface to the second surface, and having a single directional orientation therebetween, wherein the opening is sized to receive a post positioned on the radially outboard end of the blade structure.