Turbine Duct Assembly with Integral Bracket via Electroforming
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Solution Overview
Problem
Traditional duct assemblies in turbine engines face issues with local stress increases at the interface between the bracket and the duct, leading to reduced durability and increased operational costs, along with the need for separate joining processes that add weight and complexity.
Innovation Solution
A duct assembly with a unitarily formed metal layer that integrates the attachment joint, using a sacrificial mandrel for electroforming a metallic tubular element, which reduces stress concentrations and eliminates the need for separate joining processes, while providing additional support and durability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional separate joining processes are used to attach the duct to the bracket, then the duct assembly can be assembled, but stress concentrations occur at the interface leading to reduced durability
Solution Approach 1:
The patent merges the bracket and duct section into a single unitary structure where the bracket is integrally formed with the duct. This eliminates the interface between separate components, thereby eliminating stress concentrations that would occur at joining interfaces. The integral structure ensures continuous material flow and uniform stress distribution throughout the assembly.
2Ease of manufacture
If separate joining processes are used to attach the duct to the bracket, then the components can be assembled, but additional weight and complexity are introduced
Solution Approach 1:
The bracket and duct section are formed as a single integral component, eliminating the need for separate joining processes such as welding, brazing, or mechanical fastening. This reduces assembly complexity to a single piece installation while also reducing the overall weight by eliminating joining materials and redundant structural features.
3Strength
If traditional duct assemblies with separate components are used, then the duct can be installed, but the interface between bracket and duct creates stress increases
Solution Approach 1:
By forming the bracket and duct as a unitary structure, the patent eliminates the interface where stress concentrations would occur in traditional assemblies. The continuous material flow and lack of joints ensure uniform stress distribution and eliminate weak points that would reduce overall structural strength.
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
The solution effectively redistributes stresses, increases the working lifetime of the duct assembly, reduces operational costs, and minimizes weight, enhancing the durability and efficiency of the duct assembly by integrating the bracket and duct section through a seamless metal layer.
Implementation Method 1
depositing metal on the outer surface of the sacrificial mandrel and the attachment joint to define a metallic tubular element
Data Source
AI summary
A method of forming a tubular element includes providing an attachment joint, and disposing a mandrel adjacent the attachment joint, where the mandrel can also include an outer or exposed surface. Metal can be disposed on the outer surface of the mandrel to form at least a portion of the tubular element.