Turbine Blade Tip Repair Using Ceramic-Supported Laser Build
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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 life-limited and require expensive replacements, and often necessitate the use of new materials, whereas there is a need for more cost-effective and efficient methods that utilize existing materials and find new uses for materials already in airfoil manufacturing facilities.
Innovation Solution
A method involving the use of a ceramic casting mold as a support structure for subsequent direct metal laser melting (DMLM) processes, where the ceramic core and shell serve as a build surface for forming blade tips, allowing for the deposition of metallic powder and laser fusion to create the tip components, and the ceramic can be removed post-manufacturing through mechanical or chemical means.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional casting methods are used to manufacture turbine blades with tips, then the manufacturing process is well-established and reliable, but the process is time-consuming and costly, especially for tip replacements
Solution Approach 1:
The invention separates the turbine blade into two parts: the existing blade body (airfoil) and the new tip component. The tip is manufactured separately using additive manufacturing technology and then joined to the blade body, allowing the tip to be produced more efficiently while maintaining the reliability of the overall manufacturing process through proven joining methods
Solution Approach 2:
The invention changes the manufacturing parameters and methods for the tip portion specifically, using direct metal laser melting (DMLM) additive manufacturing technology with controlled cooling rates to achieve desired microstructures, while the blade body continues to use traditional casting methods, thus improving productivity for the tip without compromising overall reliability
2Reliability
If new materials are used for turbine blade tips, then material performance can be optimized, but the cost increases and waste is generated from unused materials
Solution Approach 1:
The invention uses the same superalloy material (such as Hastelloy, Inconel, Rene alloys, or Haynes alloys) for both the blade body and the tip component, ensuring material homogeneity and compatibility. This eliminates material waste from unused materials while maintaining optimized material performance through consistent material properties and compatible thermal expansion characteristics
Solution Approach 2:
The additive manufacturing process deposits material layer-by-layer only where needed to form the tip geometry, significantly reducing material waste compared to traditional subtractive methods. Any excess powder can be recovered and reused in subsequent manufacturing operations, further minimizing material loss
3Manufacturing precision
If complex tip geometries are manufactured using traditional methods, then manufacturing precision can be achieved, but the process becomes extremely time-consuming and costly
Solution Approach 1:
The invention replaces traditional mechanical machining and casting methods with direct metal laser melting (DMLM) additive manufacturing technology. This allows complex tip geometries to be built layer-by-layer with high precision directly from digital models, dramatically reducing manufacturing time while maintaining or improving geometric accuracy through computer-controlled deposition and solidification processes
4Strength
If turbine blades are designed with closed tips, then structural integrity is improved, but the manufacturing complexity and cost increase significantly
Solution Approach 1:
The invention segments the manufacturing process into two independent parts: the existing blade body and the separately manufactured tip. The tip is produced using additive manufacturing and then joined to the blade body using proven welding or brazing techniques. This segmentation maintains structural integrity through reliable joining while simplifying manufacturing complexity by using established processes for each component
Solution Approach 2:
The final turbine blade becomes a composite structure combining traditionally cast blade body material with additively manufactured tip material. The two materials are joined through metallurgical bonding (welding or brazing) to create a unified structure with improved integrity, while the manufacturing complexity is managed by using appropriate joining technologies for each material interface
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 is cost- and time-effective, utilizing existing materials and enabling the production of high-quality turbine components with controlled microstructures, such as single-crystal or directionally solidified structures, while avoiding the need for new materials and reducing waste.
Implementation Method 1
irradiating at least a portion of the metallic powder to form a fused layer
Implementation Method 2
direct metal laser melting (DMLM) processes
Data Source
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.