Titanium Component Groove Insert via Powder Densification
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Solution Overview
Problem
Existing methods for forming titanium components, such as those used in gas turbine engines, face challenges in achieving dimensional accuracy and mechanical robustness while being cost-effective, as they often require expensive forging and allow excessive freedom of movement during processing, limiting practical application.
Innovation Solution
A method involving a metal preform with a groove that is encapsulated to create a cavity filled with titanium alloy powder, densified through hot isostatic pressing, and then consolidated with unconsolidated composite material to form a unitary structure, eliminating the need for substantial forging and ensuring dimensional accuracy.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a substantial forging is used to ensure accurate positioning and shape of composite material, then dimensional accuracy and mechanical robustness are improved, but manufacturing cost increases significantly
Solution Approach 1:
The manufacturing process is divided into distinct stages: forming a metal preform with groove, encapsulating with form, filling cavity with powder, densifying powder to create insert form, shaping insert form, filling with composite material and powder, then consolidating. This segmentation allows each stage to be optimized independently, replacing the need for expensive substantial forging while maintaining dimensional accuracy through controlled consolidation processes.
Solution Approach 2:
The invention changes the physical state and density parameters of materials during processing. Metal powder is densified to replicate the cavity as a solid insert form, then composite material and remaining powder are consolidated through controlled densification. These parameter changes enable achievement of forging-like density and accuracy without the high costs of substantial forging operations.
2Ease of manufacture
If composite material is allowed freedom of movement within capsule during processing, then ease of manufacture is improved, but dimensional accuracy and position control deteriorate
Solution Approach 1:
A metal preform with groove is formed first, then encapsulated with a form before filling with powder and composite material. This preliminary action creates a constrained environment that maintains dimensional accuracy and position control throughout subsequent processing, while still allowing the composite material to be easily introduced and consolidated without excessive movement.
3Manufacturing precision
If a rigid annular disc is used to ensure dimensional accuracy of composite ring, then manufacturing precision is improved, but device complexity increases
Solution Approach 1:
The invention uses nested structures: a metal preform with groove is encapsulated within a form, then filled with powder that is densified to create an insert form, which is then filled with composite material. This nesting of forms within forms provides the necessary rigidity and dimensional control without requiring a separate rigid annular disc, thereby maintaining manufacturing precision while avoiding additional device complexity.
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 reduces manufacturing costs by allowing the use of lower-grade titanium and enables the production of composite rings with tailored properties in specific regions, enhancing strength and fatigue resistance, while maintaining dimensional accuracy and mechanical capabilities.
Implementation Method 1
the metal powder in the cavity is densified to a solid state by hot isostatic pressing (HIP) of the metal powder after evacuation and off gassing at high temperature
Implementation Method 2
the unconsolidated composite material and the alloy powder in the metal powder cavity insert form are densified and consolidated by a hot isostatic pressing (HIP) process after evacuation and degassing
Data Source
AI summary
In order to create titanium components with a titanium composite insert, a method is provided whereby an initial pre form 1 has a groove 2 formed in it. An encapsulating member 4 is then provided about the groove 2 in order to create a cavity 5 which is filled with titanium alloy powder 6. This titanium alloy powder 6 is densified and then accurately machined in order to create a groove insert form 7 which can accommodate a titanium composite material pre form insert 8 and further titanium alloy powder 9 such that through a high temperature isostatic pressing (HIP) process, the insert 8 is embedded. The original component form 1 can then be machined in order to create the final component elements such as aerofoils 13.