Turbine Airfoil Tip Build Surface for Ceramic-Supported DMLM
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Solution Overview
Problem
Current methods for manufacturing and repairing turbine blades and vanes are time-consuming and costly, particularly at the tips, which are prone to damage and require expensive replacement, and often necessitate the use of new materials, whereas existing materials in airfoil manufacturing facilities are not fully utilized.
Innovation Solution
The method involves using a ceramic casting mold with an internal core and external shell as a support structure for direct metal laser melting (DMLM) to additively manufacture turbine blade tips, leveraging the ceramic's high strength and inert properties to create a cost-effective and time-efficient process that reuses existing materials and maintains the microstructure of the airfoil.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If traditional welding methods are used to join turbine blade tips, then the blade can be repaired or extended, but the process is time-consuming and costly due to the complexity of superalloy welding
Solution Approach 1:
The patent replaces traditional mechanical welding processes with direct metal laser melting (DMLM) additive manufacturing. Instead of using welding equipment and procedures to join blade tips, the invention uses laser-based additive manufacturing to directly deposit and fuse metal powder onto the blade tip area, eliminating the complex welding operations and significantly reducing production time and cost.
2Reliability
If new materials are used for manufacturing turbine blade tips, then the microstructure and quality can be maintained, but the cost increases and existing materials in facilities are not utilized
Solution Approach 1:
The patent changes the manufacturing parameters and process method rather than changing the material itself. By using DMLM additive manufacturing with existing superalloy powders, the invention maintains the same material composition and microstructure quality as traditional casting methods while eliminating the need for expensive new materials. The process parameters (laser power, scan speed, layer thickness) are optimized to achieve the desired microstructure.
Solution Approach 2:
The invention enables the manufacturing facility to use its existing superalloy powder inventory for blade tip production through DMLM, rather than requiring procurement of new specialized materials. The additive manufacturing process allows the facility to self-sufficiently produce blade tips using materials already available in their supply chain, reducing material costs and waste.
3Productivity
If ceramic cores are removed from turbine blades after casting, then cooling chambers can be formed, but the process requires additional steps and time
Solution Approach 1:
The patent incorporates the ceramic core removal step into the overall process planning from the beginning. The ceramic core is designed with specific features (such as soluble materials or removable structures) that allow for efficient removal after casting. The process sequence is optimized so that core removal is performed at the most convenient time, and the additive manufacturing of blade tips is coordinated with this timing to minimize total production time and complexity.
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 production time and costs by utilizing existing materials and equipment, ensuring the quality of the additively manufactured tip matches the airfoil's microstructure, while allowing for efficient removal of the ceramic core post-manufacturing, thus extending the life of turbine components.
Implementation Method 1
direct metal laser melting (DMLM) to additively manufacture turbine blade tips
Implementation Method 2
molten alloy powder is deposited on the tip plate 50 in one or more passes
Implementation Method 3
leveraging the ceramic's high strength and inert properties to create a cost-effective and time-efficient process
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.