Turbomachine Drum Inertial Friction Welding Angular Positioning
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current methods for manufacturing turbomachine drums with coaxial rotor discs face challenges in achieving precise angular positioning and aerodynamic coupling between discs of similar radial dimensions, leading to inaccuracies in material collapse control and limitations in noise reduction and performance optimization.
Innovation Solution
A method involving coaxial positioning and inertial friction welding of discs with a rotating wall of revolution, allowing for precise angular alignment and two-phase welding to secure the discs, enabling multi-stage aerodynamic coupling regardless of disc diameter, and using a less expensive material for the wall of revolution.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If broaching is performed after friction welding, then precise angular positioning of discs is achieved, but this is only possible when the downstream disc has a significantly larger diameter than the upstream disc
Solution Approach 1:
The cells of the downstream disc are formed by broaching before friction welding, in advance of the welding operation. This preliminary formation of cells allows subsequent angular positioning and welding without requiring the downstream disc to have a significantly larger diameter, thereby resolving the contradiction between achieving precise angular positioning and applying the method to discs of similar dimensions.
2Reliability
If the wall of revolution is made of the same material as the discs, then material compatibility is ensured, but precise control of material collapse level at the weld zone is not achieved
Solution Approach 1:
The wall of revolution is made of a different material than the discs, with specific attention to controlling the material collapse level (amount of material deforming under temperature) at the weld zone. This local differentiation in material properties allows precise control of axial positioning while maintaining overall assembly reliability through careful material selection and matching.
3Ease of manufacture
If inertial friction welding is used to assemble rotor discs, then assembly is achieved, but no solution is provided for aerodynamic coupling between consecutive rotor blades
Solution Approach 1:
The cells of the downstream disc are formed by broaching before friction welding, in advance of the welding operation. This preliminary formation of cells allows subsequent angular positioning and welding without requiring the downstream disc to have a significantly larger diameter, thereby resolving the contradiction between achieving precise angular positioning and applying the method to discs of similar dimensions.
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 method ensures precise axial positioning and aerodynamic coupling, improving turbomachine performance and reducing noise emissions, while allowing for cost-effective material usage by using a less expensive alloy for the wall of revolution.
Implementation Method 1
bring the disks into contact with the ends of the wall of revolution and thus achieve inertial friction welding of the disks on the wall of revolution
Implementation Method 2
achieve inertial friction welding of the disks on the wall of revolution
Data Source
Figure 1~3
AI summary
Process for manufacturing a turbomachine drum (52), comprising at least two rotor discs (46, 48), the process consisting in positioning the two discs (46, 48) coaxially at a certain distance apart and in a predetermined angular position one with respect to the other, in placing an axisymmetric wall (50) coaxially between the two discs (46, 48), rotating the axisymmetric wall (50) about its axis and moving the discs (46, 48) axially towards the axisymmetric wall (50) so as to bring the discs (46, 48) into contact with the ends of the axisymmetric wall (50) and to weld the discs (46, 48) to the axisymmetric wall (50) by inertial friction welding.