Turbine Labyrinth Seal Additive Build for Precision Teeth
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Solution Overview
Problem
Conventional manufacturing processes for turbine labyrinth seals result in significant material loss and high costs due to complex machining and cutting, especially for the tooth part, and existing 3D printing methods using metal powder are expensive and inefficient.
Innovation Solution
A method utilizing wire arc additive manufacturing for the body part and directed energy deposition for the tooth part, incorporating a hollow design with a space part to reduce weight and material waste, and applying ultrasonic vibration and infrared radiation for improved deposition.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional machining and cutting processes are used to manufacture the tooth part, then manufacturing precision can be achieved, but material loss increases significantly (50% to 70%)
Solution Approach 1:
The patent replaces conventional mechanical machining and cutting processes with wire arc additive manufacturing (WAAM) technology to manufacture the tooth part. This substitution eliminates the need for material removal, achieving near-net-shape manufacturing with material loss reduced from 50-70% to minimal levels, while maintaining manufacturing precision through controlled deposition processes
Solution Approach 2:
The patent changes the manufacturing approach from subtractive (machining/cutting) to additive (wire arc deposition). By altering the fundamental manufacturing parameter from material removal to material addition, the process achieves both high precision tooth geometry and dramatic reduction in material loss, transforming the production paradigm for the tooth part
2Loss of substance
If wire arc additive manufacturing is used for the tooth part, then material loss is reduced, but manufacturing precision for thin and sharp features deteriorates
Solution Approach 1:
The patent divides the labyrinth seal into two distinct parts with different manufacturing methods: the body part is manufactured using wire arc additive manufacturing (reducing material loss), while the tooth part is manufactured using directed energy deposition (maintaining precision for thin and sharp features). This segmentation allows each part to be optimized by the most suitable process
Solution Approach 2:
The patent applies different manufacturing qualities and processes to different parts of the same component. The body part receives the benefits of WAAM for cost-effectiveness and material efficiency, while the tooth part receives the precision of directed energy deposition. This local differentiation of manufacturing quality ensures both material efficiency and geometric precision where needed
3Manufacturing precision
If metal powder is used for 3D printing, then manufacturing precision can be improved, but cost increases significantly
Solution Approach 1:
The patent replaces expensive metal powder with cost-effective wire material for the 3D printing process. Wire arc additive manufacturing uses consumable wire electrodes that are significantly cheaper than metal powder, reducing material costs while maintaining adequate manufacturing precision for the body part through controlled arc deposition
4Manufacturing precision
If metal powder is used for 3D printing, then manufacturing precision can be improved, but deposition speed decreases
Solution Approach 1:
The patent replaces powder-based 3D printing with wire arc additive manufacturing, substituting a powder feeding and melting system with a wire feeding and arc melting system. This substitution dramatically increases deposition speed due to the higher material deposition rate of wire-based processes, while still achieving sufficient precision for the body part geometry
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
Reduces overall weight and material waste, enhances productivity, and improves assemblability while minimizing friction and gas leakage, resulting in cost-effective and efficient turbine operation.
Implementation Method 1
the body part is manufactured by the wire arc additive manufacturing
Implementation Method 2
the tooth part is manufactured by a directed energy deposition
Implementation Method 3
applying ultrasonic vibration and infrared radiation for improved deposition
Implementation Method 4
applying ultrasonic vibration and infrared radiation for improved deposition
Data Source
Figure 1
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AI summary
The present invention relates to a method for manufacturing a labyrinth seal using wire arc additive manufacturing, which is mounted between a diaphragm of a turbine and a turbine rotor to induce a smooth rotation of the turbine rotor and preventing gas leakage by minimizing friction between the diaphragm of a turbine and a turbine rotor when a rotating body such as the turbine rotor rotates inside a fixed body such as the diaphragm, and which includes a ring-shaped body part and a tooth part protruding on one side of the ring-shaped body part, wherein the labyrinth seal is deposition-manufactured by 3D printing, the body part is manufactured by the wire arc additive manufacturing, and the tooth part is manufactured by a directed energy deposition.