Turbine Blade Erosion Shield with DED-Formed Shaped Interface
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Solution Overview
Problem
Conventional methods for manufacturing erosion-shielded turbine blades are complex and inefficient, involving multi-stage processes that increase manufacturing and repair times, downtime costs, and material sourcing challenges, while also requiring additional machining and more erosion-resistant material.
Innovation Solution
The method involves using directed energy deposition (DED) to form a pre-formed erosion shield with a layer of filler material and an erosion-resistant material, where the interface between the two materials is shaped to match the leading edge of the turbine blade, allowing for a single-step attachment and reducing material waste and costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional multi-stage processes are used to manufacture erosion-shielded turbine blades, then the erosion resistance is improved, but the manufacturing complexity and time increase
Solution Approach 1:
The patent combines multiple manufacturing operations (deposition of filler material, deposition of erosion-resistant material, and machining) into a single integrated process sequence using directed energy deposition equipment, eliminating the need for separate multi-stage processes while maintaining erosion resistance
Solution Approach 2:
The method performs preliminary deposition of filler material and erosion-resistant material in specific sequences before final machining, preparing the workpiece in advance to reduce subsequent processing steps and simplify the overall manufacturing process
2Reliability
If conventional multi-stage processes are used, then the erosion resistance is improved, but the manufacturing time increases
Solution Approach 1:
The directed energy deposition process enables continuous deposition of filler material and erosion-resistant material without interrupting the manufacturing flow, eliminating idle time between stages and significantly reducing total manufacturing time while maintaining material quality and erosion resistance
3Reliability
If conventional methods are used, then the erosion protection is improved, but the material usage increases
Solution Approach 1:
The directed energy deposition process applies erosion-resistant material only to specific regions where erosion protection is needed, and uses filler material strategically to build up geometry, minimizing unnecessary material deposition and reducing overall material waste compared to conventional coating methods
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 simplifies the fabrication process, reduces manufacturing and repair times, and minimizes material usage, thereby enhancing operational efficiency and extending the lifespan of turbine blades by protecting them from erosion.
Implementation Method 1
depositing a layer of filler material using a directed energy deposition (DED) system; depositing a layer of erosion-resistant material across the upper surface of the layer of filler material using the DED system
Data Source
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AI summary
A method of forming an erosion shield (326) for a turbine blade (300) includes depositing a layer of filler material (402 or 328) defining an upper surface (416). The method also includes depositing a layer of erosion-resistant material (422 or 330) across the upper surface (416) of the layer of filler material (402 or 328). An interface (340) is defined between the layer of filler material (402 or 328) and the layer of erosion-resistant material (422) and has a shape of the upper surface (416). The method also includes machining the layer of filler material (402 or 328) to produce the erosion shield (326). The erosion shield (326) has the layer of erosion-resistant material (422 or 330), the machined layer of filler material (328), and the interface (340) defined therebetween. An inner surface (336) of the erosion shield is defined by the machined layer of filler material (328) that is sized and shaped for attaching to a leading edge (304) of the turbine blade (300). Each of the interface (340) and the inner surface (336) extend a length of the erosion shield (326).