Turbine Blade Brazing With Sequential Heat Stabilization
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Solution Overview
Problem
The existing manufacturing method for turbine blades requires laborious reapplication of brazing material during stabilizing treatment, as the initial brazing material can melt again during heat treatment, increasing the complexity and time required for the process.
Innovation Solution
Performing brazing and stabilizing treatments simultaneously with a single heating process, eliminating the need for reapplying the brazing material, and adjusting the temperature to optimize the γ′ phase precipitation for enhanced strength and ductility, while also incorporating undercoat and topcoat formations to prevent cracking and foreign substance adhesion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the stabilizing treatment is performed by heating the base material at a temperature higher than the liquidus temperature of the brazing material, then the γ′ phase precipitated in the base material is increased, but the brazing material melts again causing a break of the brazing material
Solution Approach 1:
The patent combines the stabilizing treatment and brazing treatment into a single heating process. The brazing material is applied to the base material before heating, and both treatments are performed simultaneously at a temperature higher than the liquidus temperature of the brazing material. This eliminates the need for separate treatment steps and prevents the brazing material from melting again during stabilizing treatment, as the brazing material is already in place to withstand the heating process.
Solution Approach 2:
The brazing material is applied to the base material in advance before the heating process. This preliminary action ensures that the brazing material is already positioned and prepared to withstand the stabilizing treatment heating, preventing it from melting again during the process. The brazing material is applied at a stage when it can be securely attached to the base material, ensuring its integrity during subsequent high-temperature treatment.
2Reliability
If the stabilizing treatment requires work of adding the brazing material to the base material, then the brazing material integrity is maintained, but the manufacturing burden increases
Solution Approach 1:
The patent merges the stabilizing treatment and brazing treatment into a single integrated process. The brazing material is applied to the base material before heating, and both treatments are performed simultaneously in one heating step. This eliminates the need for separate brazing material addition steps during stabilizing treatment, significantly reducing manufacturing burden while maintaining brazing material integrity through the combined process design.
Solution Approach 2:
The single heating process serves multiple functions simultaneously: it performs both the stabilizing treatment (heating the base material to precipitate γ′ phase) and the brazing treatment (melting and joining the brazing material). This multi-functional approach eliminates the need for separate treatment steps and associated material handling, reducing manufacturing complexity and burden while achieving both treatment objectives in one operation.
3Manufacturing precision
If the brazing treatment and stabilizing treatment are performed separately, then each treatment can be optimized, but the treatment time increases
Solution Approach 1:
The patent combines the brazing treatment and stabilizing treatment into a single heating process performed simultaneously. The heating conditions are optimized to achieve both treatments in one step: the temperature is maintained above the liquidus temperature of the brazing material to ensure proper brazing while also providing the necessary conditions for γ′ phase precipitation in the base material. This eliminates the need for separate treatment steps, significantly reducing total treatment time while maintaining optimization of both processes through carefully controlled heating parameters.
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 reduces manufacturing burdens by streamlining the process, shortening treatment times, and enhancing the mechanical properties of turbine blades through optimized γ′ phase formation and thermal barrier coatings, thereby improving efficiency and preventing cracks in the topcoat.
Implementation Method 1
brazing treatment for joining a brazing material to a base material of a turbine blade by heating the base material having the brazing material arranged thereon and melting the brazing material
Implementation Method 2
a first temperature higher than a liquidus temperature of the brazing material, at which a γ′ phase precipitated in the base material is increased
Data Source
AI summary
A method of manufacturing a turbine blade includes a brazing treatment for joining a brazing material to a base material of a turbine blade by heating the base material having the brazing material arranged thereon and melting the brazing material, a stabilizing treatment for heating the base material having been subjected to the brazing treatment; and an aging treatment for heating the base material having been subjected to the stabilizing treatment. The brazing treatment and the stabilizing treatment are performed with a sequential heating treatment.