Turbine Blade Fusion Welding via Additive Connecting Body
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Solution Overview
Problem
Conventional methods for connecting turbine blades or vanes to turbine disks or rings in turbomachines face challenges such as inadequate connection strength, high apparatus requirements, and thermal incompatibility, especially when using nickel base alloys, which are not suitable for fusion welding.
Innovation Solution
A method involving the formation of a connecting body on the turbine blade or vane using an additive suitable for fusion welding, melted by a laser or electron beam, and subsequently connected to the turbine disk or ring using a fusion welding process, allowing for high connection strength without mechanical stress on the surface.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If friction welding or diffusion welding processes are used to connect turbine blades to turbine disks, then connection strength is improved, but apparatus outlay and process complexity increase significantly
Solution Approach 1:
A connecting body made of fusion-weldable material is introduced as an intermediary component between the turbine blade and turbine disk. This connecting body is first cold-sprayed onto the turbine blade surface, then fusion-welded to both the blade and the disk, enabling connection strength comparable to friction or diffusion welding while using simpler, more cost-effective equipment
Solution Approach 2:
The invention changes the material parameter of the connection interface by applying a coating of fusion-weldable material (such as nickel-based alloy powder) onto the surface of the turbine blade through cold spraying. This parameter change enables the use of conventional fusion welding processes instead of complex friction or diffusion welding equipment
2Device complexity
If cold spraying process is used to form a connecting body on turbine blades, then apparatus outlay is reduced, but connection strength becomes inadequate for turbine applications
Solution Approach 1:
The invention merges two processes: first, cold spraying to apply the fusion-weldable material coating onto the turbine blade surface with low apparatus outlay; second, fusion welding to connect this coating to the turbine disk. The combination of these two processes achieves both low equipment cost and high connection strength suitable for turbine applications
Solution Approach 2:
The connecting body is prepared in advance by cold spraying the fusion-weldable material onto the turbine blade surface before the actual welding operation. This preliminary action creates a suitable interface that can subsequently be strong fusion-welded to both the blade and disk
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 achieves a strong and stable connection between turbine blades or vanes and disks or rings with reduced apparatus demands, avoiding material stress and thermal issues, thus enabling efficient production with high connection strength.
Implementation Method 1
The melting of (b) may be effected by a laser beam and/or an electron beam that is guided over the surface
Implementation Method 2
The melting of (b) may be effected by a laser beam and/or an electron beam that is guided over the surface
Implementation Method 3
melting the additive on the surface of the turbine blade or vane, with incipient melting of the surface
Implementation Method 4
allowing the additive and the surface to solidify
Implementation Method 5
connecting the connecting body to the turbine disk or the turbine ring by a fusion welding process
Data Source
AI summary
The present invention provides a method for connecting a turbine blade or vane to a turbine disk or to a turbine ring. First, a connecting body is formed on the turbine blade or vane by supplying an additive suitable for fusion welding to a surface of the turbine blade or vane, melting the additive on the surface, with incipient melting of the surface, and allowing the additive and the surface to solidify. Then, the connecting body is connected to the turbine disk or to the turbine ring by means of a fusion welding process.