Turbomachine Diffuser-Rectifier Assembly Using Sheet Metal Brazing

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Solution Overview

Problem

The manufacturing of radial diffusers and cylindrical rectifiers for turbomachines is challenging due to high scrap rates and limited supplier capabilities, resulting in high costs and supply issues, primarily because of the complexity and material requirements for machining thin blades and flanges.

Innovation Solution

A diffuser-rectifier assembly using sheet metal for annular flanges and cylindrical shrouds with radially oriented vanes, where the blades are soldered and brazed into openings, simplifying the manufacturing process and reducing material needs, and employing laser cutting and electrochemical machining for precise blade integration.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If traditional machining methods (cutting in the mass, foundry, mechanical welding) are used to manufacture diffuser and rectifier components, then structural strength and reliability are maintained, but manufacturing complexity and cost increase significantly

Engineering Contradiction:

Improvemanufacturing simplicityVSAvoidmanufacturing process complexity

Core Design Contradiction:

Ease of manufactureVSDevice complexity

Solution Approach 1:

The diffuser and rectifier are divided into separate modular components: the diffuser body with its own blades, and the rectifier with separate vanes. Each component can be manufactured independently using sheet metal forming and joining techniques, allowing parallel production and simplifying the overall manufacturing process while maintaining structural integrity through designed connection interfaces.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Traditional mechanical machining and welding processes are replaced with sheet metal forming, laser cutting, and brazing technologies. This substitution enables more efficient manufacturing of thin-walled components with complex geometries, reducing both manufacturing complexity and cost while maintaining the required mechanical strength and reliability of the components.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Quantity of substance

If sheet metal is used for diffuser flanges and rectifier shells, then manufacturing cost and material usage are reduced, but structural strength may be compromised

Engineering Contradiction:

Improvematerial usageVSAvoidstructural strength

Core Design Contradiction:

Quantity of substanceVSStrength

Solution Approach 1:

The invention employs thin sheet metal flanges and shells for the diffuser and rectifier components. These thin-walled structures are designed with optimized geometries and reinforcement features that maintain sufficient structural strength and rigidity while dramatically reducing material consumption and manufacturing cost compared to traditional thick-walled machined components.

Inventive Principle:

Principle #30Flexible shells and thin films

Solution Approach 2:

The assembly combines sheet metal components with brazed joints to create a composite structure. The sheet metal provides the lightweight, cost-effective housing and structural framework, while the brazed connections provide strong, rigid joints that maintain overall structural integrity. This composite approach balances material efficiency with mechanical strength requirements.

Inventive Principle:

Principle #40Composite materials

3Productivity

If blades and vanes are brazed into openings in sheet metal flanges, then manufacturing efficiency and cost are improved, but precision and reliability of joints become critical

Engineering Contradiction:

Improvemanufacturing efficiencyVSAvoidjoint precision

Core Design Contradiction:

ProductivityVSManufacturing precision

Solution Approach 1:

The blades and vanes are designed with pre-formed attachment features (such as tabs or engagement structures) that align with corresponding openings in the sheet metal flanges before brazing. This preliminary positioning ensures precise alignment and consistent joint quality, reducing the precision requirements during the actual brazing operation while maintaining high manufacturing efficiency and reliability.

Inventive Principle:

Principle #10Preliminary action

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 solution significantly reduces manufacturing complexity and costs by at least 30% while ensuring mechanical strength and simplifying the production process, overcoming the limitations of traditional machining methods.

Implementation Method 1

the openings in the sheets are formed by laser cutting

Methodology Applied

Scientific EffectLaser cutting: Laser Ablation

Implementation Method 2

substantially radial vanes fixed by soldering to the cylindrical shrouds

Methodology Applied

Scientific EffectSoldering: Soldering

Implementation Method 3

the ends of the blades are engaged and brazed in the openings which are formed in the flanges of the diffuser

Methodology Applied

Scientific EffectBrazing: Brazing

Implementation Method 4

The diffuser vanes and those of the stator can be produced by ECM electrochemical machining

Methodology Applied

Scientific EffectElectrochemical machining: Electrical Discharge Machining

Data Source

PatentEP1882821B1Nozzle-synchronising ring assembly for a turbomachine

Publication Date: 2013.04.10 SN DETUDE & DE CONSTR DE MOTEURS DAVIATION (S N E C M A)

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AI summary

Diffuser-rectifier assembly (10) for aircraft turbojet or turboprop, the diffuser (12) comprising annular flanges (22, 24) connected by vanes (26) and the rectifier (14) comprising cylindrical ferrules (28, 30) connected by vanes (32), the annular flanges and the cylindrical ferrules being formed of sheets to which the vanes (26, 32) are assembled by brazing.