Turbine Vane Restoration via Mechanical Force Application
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Solution Overview
Problem
Conventional systems for restoring distorted turbine airfoils are time-consuming and inefficient, particularly in removing twist and other distortions such as lean and racking, which negatively affect turbine engine performance and the lifecycle of airfoil components.
Innovation Solution
A system for reconfiguring turbine vanes using a fixture with retention arms and a force application device to apply loads to the airfoil at room temperature, allowing for adjustments up to four degrees without surface cracking, and subsequent heat treatments to stabilize the airfoil.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional furnace cycle is used to remove twist from airfoil, then twist removal is achieved, but the process becomes very time consuming
Solution Approach 1:
The patent replaces the thermal field (furnace cycle) with a mechanical field system consisting of a fixture, retention arms, and force application device. This mechanical system directly applies controlled forces to the airfoil to correct twist, lean, and rack distortions, eliminating the need for time-consuming thermal processing while achieving the same geometric correction objectives.
Solution Approach 2:
The patent changes the fundamental parameter of the correction process from thermal parameters (temperature, heat treatment duration) to mechanical parameters (applied force magnitude, force application points, fixture constraints). This parameter transformation enables much faster correction times while maintaining the ability to achieve precise geometric corrections.
2Manufacturing precision
If force is applied to airfoil to straighten it, then distortion is removed, but surface microcracks may occur
Solution Approach 1:
The patent applies force at specific localized regions of the airfoil rather than uniformly across the entire structure. The force application device targets specific areas to induce controlled deformation in the distorted regions while leaving other areas undisturbed, thereby correcting shape without creating widespread stress concentrations that could lead to cracking.
Solution Approach 2:
The patent applies force incrementally and partially, correcting distortions to within tolerances rather than attempting perfect straightening. The system applies just enough force to achieve the required geometric specifications, avoiding excessive force application that would create harmful stress concentrations and surface cracks.
3Manufacturing precision
If multiple distortion conditions are corrected, then airfoil performance is improved, but the system complexity increases
Solution Approach 1:
The patent designs a universal fixture system that can correct multiple types of distortions (twist, lean, rack) using the same basic mechanical components. The retention arms and force application device can be reconfigured to address different distortion modes, eliminating the need for separate specialized equipment for each correction type and simplifying the overall 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
Enables efficient reconfiguration of turbine vanes within predetermined specifications without preheating, improving engine performance and extending the lifecycle of airfoil components by minimizing cracking and optimizing alignment.
Implementation Method 1
The force application device may be positioned in various positions to apply a desired load to the turbine vane
Implementation Method 2
subsequent heat treatments to stabilize the airfoil
Data Source
AI summary
A system and method for reconfiguring a turbine vane. In at least one embodiment, the system may be used to straighten an airfoil of a turbine vane segment to remove lean, twist, or racking, or any combination thereof. The airfoil may be straightened by fixing portions of the forward and aft hooks of the inner and outer shrouds of the turbine vane, restricting other portions of the forward and aft hooks of the inner and outer shrouds of the turbine vane to only move rotationally about a centerline of the inner or outer shrouds, and applying a load to various portions of the inner and outer shrouds and the airfoil to return the turbine vane to be within predetermined specifications.