Additively Manufactured Turbine Engine Ducts With Variable Profiles
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Solution Overview
Problem
Duct assemblies in turbine engines face limitations due to manufacturing constraints, leading to increased weight and inefficiency, and require rigidity under dynamic loading and flexibility under thermal loading, while also needing to accommodate complex engine components.
Innovation Solution
The development of ducts with variable profiles, thicknesses, and tight bends, formed using additive manufacturing and low-temperature metal deposition, allowing for improved maneuverability and adaptability to engine spaces, and incorporating bellows for flexible joints.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If traditional duct assemblies are used with standard manufacturing capabilities, then manufacturing is easier and costs are lower, but weight increases and duct efficiency decreases
Solution Approach 1:
The patent applies parameter changes by transitioning from traditional uniform duct designs to variable-profile ducts with optimized thickness distributions. The duct incorporates varying wall thicknesses and cross-sectional dimensions along its length, allowing material to be concentrated where structurally necessary while reducing weight in less critical areas. This parameter optimization resolves the contradiction by enabling weight reduction without sacrificing manufacturing feasibility, as the variable parameters are achieved through controlled forming processes.
Solution Approach 2:
The patent utilizes composite material structures by combining different material properties within the duct assembly. The duct incorporates zones with different material compositions or thicknesses to achieve optimal strength-to-weight ratios. This composite approach allows the duct to maintain structural integrity while reducing overall weight, resolving the contradiction between ease of manufacture and weight efficiency.
2Strength
If ducts are made rigid to withstand dynamic loading, then structural strength improves, but flexibility under thermal loading decreases
Solution Approach 1:
The patent applies segmentation by dividing the duct into distinct zones with different structural characteristics. Certain sections are designed with higher rigidity to withstand dynamic loading, while other sections incorporate flexibility features to accommodate thermal expansion and contraction. This segmentation resolves the contradiction by distributing structural and flexible properties to different parts of the duct assembly.
Solution Approach 2:
The patent implements dynamics by designing the duct with variable stiffness characteristics along its length. The duct transitions from rigid sections to more flexible sections, allowing it to dynamically adapt to different loading conditions. This dynamic design enables the duct to maintain structural strength under dynamic loading while providing necessary flexibility under thermal loading conditions.
3Adaptability or versatility
If complex ducting paths are created to accommodate engine components, then adaptability to engine spaces improves, but manufacturing complexity and cost increase
Solution Approach 1:
The patent applies dimensionality change by utilizing three-dimensional forming techniques to create complex duct paths that would traditionally require multiple separate components. The duct is formed with variable cross-sections and spatial configurations that accommodate engine components while maintaining a single-integral structure. This approach resolves the contradiction by achieving high adaptability to engine spaces without increasing assembly complexity, as the complex geometry is achieved through advanced forming rather than multiple parts.
4Strength
If duct thickness is increased to improve structural integrity, then strength improves, but weight increases
Solution Approach 1:
The patent applies local quality by varying the duct thickness locally rather than uniformly throughout. Critical sections requiring high structural integrity are designed with increased thickness, while non-critical sections use reduced thickness to minimize weight. This local quality approach resolves the contradiction by providing structural integrity where needed while reducing overall weight through strategic thickness optimization.
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 provides ducts with enhanced structural integrity, reduced weight, and improved fluid flow management, while fitting into crowded engine spaces, thus optimizing engine performance and efficiency.
Implementation Method 1
formed using additive manufacturing and low-temperature metal deposition
Implementation Method 2
formed using additive manufacturing and low-temperature metal deposition
Implementation Method 3
incorporating bellows for flexible joints
Data Source
Figure 1
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Figure 6
AI summary
A duct (100) for a turbine engine (10), such as a gas turbine engine, can be utilized to carry a fluid from one portion of the engine (10) to another. The duct (100) can include a metallic tubular element (101) having one of a varying wall thickness, a varying cross section, or a tight bend (132). Such a duct (100) can be formed utilizing additive manufacturing or metal deposition on an additively manufactured mandrel (486).