Turbomachine Rotor Disk Fabrication Using Segmented Metal Container
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Solution Overview
Problem
Existing methods for fabricating turbomachine rotor disks with annular reinforcing inserts of composite material are inefficient due to lengthy and expensive hot isostatic compression processes, and require costly welding steps for assembling integrally-bladed rotors.
Innovation Solution
A method involving a metal container with coaxial annular blocks and side plates forming cavities, where composite inserts are positioned and subjected to hot isostatic compacting to form a one-piece blank, allowing for machining into a rotor disk, enabling integration of long inserts and potentially multiple inserts in a single operation, and subsequent machining to create either single or multiple disks or bladed rotors.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the prior method of forming a metal matrix with an annular composite insert is used, then the composite insert is integrated into the metal structure, but the hot isostatic compression operation becomes lengthy and expensive
Solution Approach 1:
The invention divides the metal structure into multiple separate blocks (first annular metal block, second annular metal block, and intermediate annular metal block) that are assembled together with the composite insert between them, avoiding the need for lengthy hot isostatic compression to integrate a single large insert. The metal blocks are segmented to accommodate the insert while maintaining structural integrity through mechanical assembly rather than prolonged thermal compression.
2Ease of manufacture
If the prior method is used to create integrally-bladed rotors, then individual disks can be fabricated, but welding is required after each IBR fabrication which increases cost and risk
Solution Approach 1:
The invention combines multiple metal blocks and the composite insert into a single assembled structure that forms the integrally-bladed rotor directly, eliminating the need for subsequent welding operations. The blocks are joined mechanically during assembly rather than requiring post-fabrication welding, thereby reducing both cost and risk associated with welding operations on expensive IBRs.
3Strength
If the prior method is used, then short inserts can be integrated, but inserts of considerable axial length cannot be made
Solution Approach 1:
The metal structure is divided into multiple blocks along the axial direction, with the composite insert positioned between them. This segmentation allows the insert to span considerable axial lengths by distributing the structural support across multiple metal blocks rather than requiring a single continuous metal mass, thereby enabling integration of longer inserts that would be impossible with the prior single-block approach.
4Manufacturing precision
If multiple inserts are integrated in separate operations, then each insert can be properly compacted, but the number of hot isostatic compression operations increases time and expense
Solution Approach 1:
The invention merges multiple metal blocks and multiple composite inserts into a single assembled structure that can be compacted in one hot isostatic compression operation. By positioning multiple inserts between the segmented metal blocks and then performing a single compression operation on the entire assembly, the method achieves proper compaction of all inserts simultaneously, thereby reducing the total number of compression operations from multiple separate processes to one unified process, improving both productivity and reducing expense.
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 reduces the time and expense of hot isostatic compacting by enabling the creation of disks with integrated inserts in a single operation, allowing for efficient production of turbomachine rotor disks and integrally-bladed rotors, while minimizing the need for costly welding and enabling flexible machining to produce either single or multiple disks.
Implementation Method 1
the assembly is subjected to hot isostatic compression. During that operation, the metal of the cover creeps into the cavity until all of the empty spaces between the turns have been filled
Implementation Method 2
the metal of the cover creeps into the cavity until all of the empty spaces between the turns have been filled
Data Source
AI summary
A method of fabricating a turbomachine rotor disk is disclosed. In the method, a metal container is defined, made up of a plurality of parts that define between them at least one annular cavity, an insert made of composite material is positioned in the at least one cavity, the assembly is subjected to hot isostatic compacting, and a rotor disk is machined.