Turbine Distributor-Casing Integration for Weld-Free Channel Machining

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

The existing methods for manufacturing turbines, particularly those with distributors, are complex and difficult due to the intricate welds required for assembling the distributor and casing, which complicates the manufacturing process.

Innovation Solution

A method involving additive manufacturing to create the distributor and casing in one piece, with subsequent material removal through techniques like spark erosion or electroerosion machining to form the channel, allowing for the integration of the hub and simplifying the manufacturing process by making the downstream face more accessible for machining.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If the distributor and casing are manufactured separately and assembled by welding, then the manufacturing process requires complex and difficult welds, but the components can be assembled using traditional methods

Engineering Contradiction:

Improveease of manufactureVSAvoiddevice complexity

Core Design Contradiction:

Ease of manufactureVSDevice complexity

Solution Approach 1:

The distributor and casing are merged into a single integrated component manufactured by additive manufacturing. This eliminates the need for separate manufacturing and welding operations, directly resolving the technical contradiction by improving ease of manufacture while reducing device complexity through component integration.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

Traditional mechanical welding operations are replaced with additive manufacturing processes. This substitution eliminates complex welding requirements and assembly operations, directly addressing the contradiction by simplifying the manufacturing process and reducing the complexity of joining operations.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Ease of operation

If the channel is manufactured by additive manufacturing followed by material removal, then the downstream face becomes more accessible for machining, but additional manufacturing steps are required

Engineering Contradiction:

Improveease of operationVSAvoidproductivity

Core Design Contradiction:

Ease of operationVSProductivity

Solution Approach 1:

The additive manufacturing process is used to preliminarily form the distributor and casing structure with the channel, positioning the downstream face in an accessible configuration before final machining operations. This preliminary action enables easier subsequent machining while maintaining overall productivity through reduced manual intervention.

Inventive Principle:

Principle #10Preliminary action

3Reliability

If intricate welds are used to attach the distributor to the casing and hub, then the components can be assembled, but the manufacturing process becomes complex and time-consuming

Engineering Contradiction:

ImprovereliabilityVSAvoidloss of time

Core Design Contradiction:

ReliabilityVSLoss of time

Solution Approach 1:

The distributor, casing, and hub are merged into a single integrated component manufactured by additive manufacturing. This eliminates all welding operations and assembly steps, directly resolving the contradiction by maintaining structural reliability while dramatically reducing manufacturing time and eliminating the loss of time associated with complex welding procedures.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

Mechanical welding and assembly operations are replaced with additive manufacturing processes. This substitution eliminates time-consuming welding steps while maintaining component reliability through the inherent strength and integrity of the additively manufactured integrated structure.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

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 and accelerates the manufacturing of turbines by enabling the production of complex geometries in a single piece, reducing the need for intricate welds and allowing for precise control over the channel's section, thereby improving manufacturing efficiency and reducing manual intervention.

Implementation Method 1

manufacture, by additive manufacturing, of the distributor provided with the said upstream portion, and of the casing in one piece with the distributor

Methodology Applied

Scientific EffectMelting: Melting

Implementation Method 2

The downstream face of the distributor is more easily accessible for the machining tool than its upstream face, especially when part of the casing and/or of the hub has also been manufactured during the manufacturing step

Methodology Applied

Scientific EffectElectrical Discharge Machining: Electrical Discharge Machining

Data Source

PatentEP3581298B1Method of manufacturing a turbine, in particular for a turbo pump

Publication Date: 2021.10.13 ARIANEGRP SAS

Figure 1A
Figure 1B
Figure 2

AI summary

Method for manufacturing a turbine (4), the turbine comprising a distributor (4d) and a casing (4h) surrounding the distributor (4d) and manufactured as a single unit with the distributor (4d), the distributor (4d) having a channel (42), the channel comprising an upstream portion (43) opening onto an upstream face (F1) of the distributor (4d) and a downstream portion (45) opening onto a downstream face (F2) of the distributor (4d), the method comprising the steps of: - manufacturing, by additive manufacturing, of the distributor (4d) having said upstream portion (43) and at least a part of the casing (4h) as a single unit with the distributor (4d), and - removing material from the distributor (4d) thus manufactured, so as to obtain said downstream portion (45).