Turbine Airfoil Tip Build Surface for Hybrid Casting and 3D Repair
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Solution Overview
Problem
Current methods for manufacturing and repairing turbine blades and vanes are time-consuming and costly, especially for the tips, which are prone to damage and require expensive replacement, and existing methods often necessitate the use of new materials or wasteful processes.
Innovation Solution
The method involves using a ceramic core and shell as a support structure for additive manufacturing, specifically direct metal laser melting, to form turbine blade tips, allowing for cost-effective and time-efficient production and repair by leveraging the ceramic's high strength and inert properties, and enabling the reuse of existing materials within airfoil manufacturing facilities.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional casting methods with ceramic cores and shells are used to manufacture turbine blades, then the blades can be produced with internal cooling passages, but the process is time-consuming and costly
Solution Approach 1:
The manufacturing process is divided into two segments: traditional investment casting for the airfoil portion with internal cooling passages, and additive manufacturing for the tip portion. This segmentation allows each method to be used where it is most effective, improving overall productivity while maintaining manufacturing precision for the cooling passages.
Solution Approach 2:
The ceramic core and shell are prepared in advance using traditional methods before the additive manufacturing step. This preliminary action allows the additive manufacturing process to focus only on forming the tip, significantly reducing total manufacturing time while ensuring the cooling passages are already properly formed.
2Reliability
If turbine blade tips are manufactured using traditional methods, then the blades can be produced, but the tips are prone to damage and require expensive replacement
Solution Approach 1:
The tip is manufactured using additive manufacturing with controlled laser parameters and build orientation, creating a different microstructure with superior mechanical properties. This parameter change in the manufacturing process results in improved tip durability and resistance to damage compared to traditionally cast tips.
Solution Approach 2:
The blade becomes a composite structure with the airfoil portion made by traditional casting and the tip portion made by additive manufacturing. This composite approach allows optimization of each portion for its specific function, with the additively manufactured tip providing enhanced durability.
3Strength
If new materials are used for manufacturing turbine blade tips, then the tips can have improved properties, but the production costs increase
Solution Approach 1:
Instead of using different materials, the invention uses parameter changes in the additive manufacturing process (laser power, scan speed, layer thickness) to optimize the microstructure and mechanical properties of the tip. This approach achieves improved strength without the cost of new materials.
Solution Approach 2:
The additive manufacturing process uses the same superalloy powder that is already available in airfoil manufacturing facilities, making the existing materials serve dual purposes. This self-service approach eliminates the need for new materials while maintaining improved tip properties through process optimization.
4Ease of manufacture
If existing materials are reused in airfoil manufacturing facilities, then production costs can be lowered, but the manufacturing process becomes more complex
Solution Approach 1:
The additive manufacturing system is integrated into the existing airfoil manufacturing facility, allowing the same facility to perform both traditional investment casting and additive manufacturing. This multi-functionality reuses existing infrastructure and materials while adding capability, rather than requiring a completely separate complex 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 reduces material waste, lowers production costs, and enables the creation of high-strength, high-temperature-resistant turbine components with improved microstructure and reduced cracking, facilitating efficient repair and replacement of damaged tips without the need for new materials.
Implementation Method 1
direct metal laser melting
Implementation Method 2
molten alloy powder is deposited
Implementation Method 3
ceramic core and shell as a support structure
Implementation Method 4
The blade tip is heated to a predetermined temperature profile, e.g., by induction heating or radiant heating
Implementation Method 5
The blade tip is heated to a predetermined temperature profile, e.g., by induction heating or radiant heating
Data Source
Figure 1
Figure 2A~2B
Figure 3A~3C
AI summary
Methods of manufacturing or repairing a turbine blade or vane are described. The airfoil portions of these turbine components are typically manufactured by casting in a ceramic mold, and a surface made up of the cast airfoil and at the least the ceramic core serves as a build surface for a subsequent process of additively manufacturing the tip portions. The build surface is created by removing a top portion of the airfoil and the core, or by placing an ultra-thin shim on top of the airfoil and the core. The overhang projected by the shim is subsequently removed. These methods are not limited to turbine engine applications, but can be applied to any metallic object that can benefit from casting and additive manufacturing processes. The present disclosure also relates to finished and intermediate products prepared by these methods.