Unitized Rotor Assembly via Additive Manufacturing

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Solution Overview

Problem

Traditional manufacturing methods for turbojet rotor assemblies are prone to premature in-service failures due to subsurface defects in cast turbine wheels, requiring extensive material processing, machining, and assembly, which increases costs and complexity.

Innovation Solution

The rotor assembly is additively manufactured using a nickel-based alloy, integrating the turbine, compressor, and shaft into a single part via layer-by-layer additive manufacturing, eliminating the need for separate components and reducing material processing, machining, and assembly, while utilizing internal cavities and structural members for structural support and weight reduction.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If traditional manufacturing methods (casting, forging, or machining) are used to produce rotor assembly components, then the components can be manufactured with established processes, but subsurface defects occur in cast turbine wheels leading to premature failures

Engineering Contradiction:

Improverotor assembly reliabilityVSAvoidmanufacturing complexity

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The patent merges the turbine portion, compressor portion, and shaft portion into a single additively manufactured unitized rotor assembly. This integration eliminates the need for separate casting, machining, and assembly operations for individual components, thereby eliminating subsurface defects associated with traditional casting while reducing overall manufacturing complexity through one-step production.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The patent replaces traditional mechanical manufacturing processes (casting, forging, machining) with additive manufacturing technology. This substitution eliminates the mechanical casting process that causes subsurface defects and premature failures, while the additive process produces defect-free components through layer-by-layer deposition of nickel-based alloy material.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Productivity

If separate components (turbine, compressor, shaft) are manufactured and assembled, then each component can be optimized independently, but the assembly process increases manufacturing time and complexity

Engineering Contradiction:

Improverotor assembly production efficiencyVSAvoidnumber of components

Core Design Contradiction:

ProductivityVSDevice complexity

Solution Approach 1:

The patent combines three separate components (turbine portion, compressor portion, shaft portion) into a single unitized rotor assembly manufactured through additive manufacturing. This merging eliminates multiple manufacturing steps and assembly operations, significantly improving production efficiency while reducing device complexity from multiple parts to one integrated component.

Inventive Principle:

Principle #5Merging (Combining)

3Manufacturing precision

If extensive material processing and machining are performed on separate components, then final dimensional accuracy can be achieved, but material costs and processing time increase

Engineering Contradiction:

Improvecomponent dimensional accuracyVSAvoidprocessing time

Core Design Contradiction:

Manufacturing precisionVSLoss of time

Solution Approach 1:

The patent replaces traditional sequential manufacturing processes (casting followed by extensive machining) with additive manufacturing that builds components layer-by-layer with built-in dimensional accuracy. This substitution eliminates the need for extensive post-processing machining while reducing processing time, as the additive process can directly produce components at final dimensions with minimal secondary operations.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

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 minimizes premature failures, reduces material costs, and enhances the rotor assembly's strength and efficiency by eliminating subsurface defects, allowing for higher operating temperatures and increased power density, while simplifying the manufacturing process.

Implementation Method 1

building the rotor assembly via layer-by-layer additive manufacturing

Methodology Applied

Scientific EffectAdditive manufacturing: 3D Printing

Data Source

PatentUS11180997B2Unitized rotor assembly

Publication Date: 2021.11.23 RTX CORP

AI summary

A method of making a rotor assembly of a turbojet includes building the rotor assembly via layer-by-layer additive manufacturing. A turbine portion is formed and a compressor portion is integrally formed with the turbine portion. A shaft portion is integrally formed with the compressor portion. A material of the rotor assembly includes a nickel based alloy.