Turbine Vane Segmented Casting with Monocrystalline Blade and Polycrystalline Foot
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Solution Overview
Problem
Current manufacturing processes for high-pressure turbine blades in turbomachines are limited by the need for monobloc, mono-material designs that are costly and heavy due to uniform material constraints, which do not efficiently address varying mechanical and temperature stresses across different parts of the blade and foot.
Innovation Solution
A process involving the formation of a monocrystalline blade and a polycrystalline foot in different metal alloys, allowing for separate optimization of materials based on specific constraints, using a nickel-based alloy for both parts to ensure a strong metallurgical link without the need for assembly stages like welding, and employing additive manufacturing for cost and time efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If monocrystalline material is used for the entire blade including root, then creep resistance and high-temperature performance are improved, but blade weight and manufacturing cost increase
Solution Approach 1:
The blade is divided into two distinct parts: a monocrystalline blade portion for high-temperature creep resistance and a polycrystalline root portion for weight reduction. This segmentation allows each part to be optimized independently for its specific functional requirements while maintaining overall structural integrity.
Solution Approach 2:
Different material structures are applied to different locations of the blade based on local stress and temperature conditions. The monocrystalline structure is used where high-temperature creep resistance is critical (blade portion), while the polycrystalline structure is used where weight reduction is prioritized (root portion).
2Temperature
If monocrystalline material is used for the entire blade, then high-temperature performance is improved, but manufacturing cost increases
Solution Approach 1:
The manufacturing process is segmented into two distinct casting operations: first forming the monocrystalline blade portion with controlled directional solidification, then forming the polycrystalline root portion. This reduces overall manufacturing complexity and cost compared to producing the entire blade as a single monocrystalline piece.
Solution Approach 2:
The invention applies different material qualities and manufacturing processes to different parts of the blade based on local performance requirements, avoiding the unnecessary cost of monocrystalline material in the root where high-temperature performance is less critical.
3Ease of manufacture
If uniform material specifications are applied to blade and root, then material selection is simplified, but overall performance is compromised due to unnecessary weight and cost
Solution Approach 1:
The blade design is segmented into two parts with different material specifications optimized for their respective functions. The blade portion uses monocrystalline material for high-temperature performance while the root uses polycrystalline material for weight reduction, achieving superior overall performance compared to uniform material selection.
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 enables the design of turbine blades with optimized material properties and reduced costs by allowing independent optimization of blade and foot materials, reducing the risk of material weakness and improving mechanical characteristics while maintaining performance.
Implementation Method 1
The shell mold gradually descends out of the hot chamber in which it is placed, which causes the directed solidification of the liquid metal from the single crystal seed
Implementation Method 2
The shell mold gradually descends out of the hot chamber in which it is placed, which causes the directed solidification of the liquid metal
Data Source
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AI summary
Disclosed is a method for manufacturing a vane (10) comprising a first portion and a second portion, the method comprising a step of forming the first portion (E1) that comprises forming a model of the first portion from removable material, then forming a first shell mould from the model of the first portion, then forming the single-crystal or columnar first portion from a first metal alloy in the first shell mould from a single-crystal seed, a step of forming the second portion (E2) in which a second portion is formed on the first portion, and in which the first portion and the second portion are made from different materials, the second portion being polycrystalline and formed from a second metal alloy. Also disclosed is a vane (10) comprising a single-crystal or columnar first portion made from a first metal alloy and a polycrystalline second portion made from a second metal alloy different from the first metal alloy.