Twisted Metal Strand Weaving for Thick Turbomachine Reinforcements
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Solution Overview
Problem
The production of metal reinforcements for turbomachine blades, particularly those with complex geometric shapes and larger diameters, is challenging due to difficulties in weaving thicker metallic fibrous structures and the need for complex tools and costly processes, which increase production costs and time.
Innovation Solution
A method involving the weaving of three-dimensional fibrous structures using metal strands twisted together, followed by hot isostatic pressing to create a solid part, allowing for manual deformation and shaping without the need for complex tools, thereby simplifying the process and reducing costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If metal wires of diameter greater than 0.4 mm are used to produce a thicker metallic fibrous structure, then the structural integrity and thickness of the part are improved, but the weaving becomes much more difficult and the stiffness of the yarns increases making deformation difficult
Solution Approach 1:
The metal strand is segmented into multiple smaller wires (e.g., 7x0.2 mm or 19x0.1 mm) twisted together to form a composite strand. This segmentation allows the strand to maintain flexibility for easy weaving while providing the thickness and structural integrity needed for the final part. The twisted construction enables the strand to deform during weaving despite being composed of multiple rigid wires.
Solution Approach 2:
The invention uses composite construction by twisting multiple metal wires together to form a strand, and then weaving multiple strands to form the fibrous structure. This composite approach combines the rigidity of individual wires with the flexibility of the twisted bundle, resolving the contradiction between thickness and weaveability.
2Strength
If conventional weaving with thick metal wires is attempted, then the structural strength is improved, but the number of operations and production cost increase due to complexity
Solution Approach 1:
The metal strands are pre-twisted into flexible bundles before the weaving process. This preliminary preparation allows the strands to be easily manipulated and woven into complex three-dimensional shapes without requiring intermediate deformation operations during the weaving process itself, thereby reducing the total number of operations.
Solution Approach 2:
The invention changes the physical parameters of the metal reinforcement by using twisted strands instead of solid wires. This parameter change (from solid to twisted construction) fundamentally alters the deformability and weaveability while maintaining structural strength, enabling a more efficient production process with fewer operations.
3Ease of operation
If heat treatment is applied to reduce the stiffness of yarns, then the ease of weaving is improved, but oxidation of titanium wires occurs degrading the quality of the part
Solution Approach 1:
The invention applies different properties to different levels of the structure: individual wires maintain their high strength and stiffness, while the twisted bundle exhibits flexibility due to the geometric arrangement. This local differentiation of properties allows the material to be both strong and easy to weave without requiring heat treatment that would cause oxidation.
4Ease of manufacture
If multiple thin fibrous structures are superimposed to achieve sufficient thickness, then the ease of weaving is improved, but the number of operations and production cost increase
Solution Approach 1:
The invention merges multiple thin wires into a single twisted strand, which then functions as one weaving element. This consolidation reduces the number of separate weaving operations needed compared to superimposing multiple thin fibrous structures. The twisted strand can be woven as a single unit while providing the combined thickness of all constituent wires.
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 enables the rapid and cost-effective production of complex, thick metal parts with reduced operational complexity, overcoming issues related to the stiffness of titanium wires and the need for multiple layers, while maintaining mechanical integrity and aerodynamic profiles.
Implementation Method 1
metal strands serving as warp yarn and weft yarn, the metal strands being formed by a plurality of metal strands twisted together around the longitudinal axis of the strand
Implementation Method 2
a step of hot isostatic pressing of said fibrous structure causing the agglomeration of the metal strands of said fibrous structure so as to obtain a solid part
Data Source
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AI summary
The present invention relates to a method for producing a solid part, comprising, in sequence: a step of weaving a three-dimensional fibrous structure (300), said weaving being carried out with metal braids (301, 302) consisting of a plurality of metal strands mutually twisted about the longitudinal axis of the braid; and a step of performing hot isostatic pressing on said fibrous structure (300) causing the agglomeration of the metal braids of said fibrous structure (300) so as to produce a solid part.