Gas Turbine Vane Inner Shroud Restoration via Thermal Deformation
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Solution Overview
Problem
Gas turbine engine parts, such as turbine vane segments, experience dimensional distortion due to thermal and aerodynamic loads, leading to displacement and potential flight safety issues, often requiring scrapping as viable repair methods are not available.
Innovation Solution
A method and apparatus to restore the inner shroud of a vane segment to its original design position and dimensions relative to the outer shroud, utilizing an apparatus with an outer shroud holding fixture, an inner shroud holding fixture, and a mechanical or hydraulic press to align and secure the inner shroud, followed by heating and cooling to achieve plastic deformation and precise alignment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If gas turbine parts are subjected to thermal and aerodynamic loads over time, then the parts operate reliably under extreme conditions, but the dimensional distortion occurs causing deviation from original specifications
Solution Approach 1:
The patent applies thermal parameter changes by heating the vane segment to elevated temperatures (e.g., 650-750°C) to enable plastic deformation of the distorted inner shroud. This temperature change allows the material to be reshaped into its original configuration, thereby restoring dimensional accuracy while maintaining operational reliability
Solution Approach 2:
The patent replaces traditional mechanical force-based realignment methods with a thermally-assisted plastic deformation process. Instead of applying complex mechanical forces to reshape the distorted shroud, the invention uses controlled heating combined with simple compressive or bending forces to achieve the desired dimensional restoration
2Ease of manufacture
If the inner shroud displaces relative to the outer shroud due to thermal loads, then the vane segment experiences distortion, but scrapping the component is required when no viable repair is available
Solution Approach 1:
The patent enables recovery of turbine vane segments that would otherwise be discarded due to shroud distortion. By applying thermal treatment and mechanical realignment, the invention restores the inner shroud to its correct position, allowing the component to be reused rather than scrapped, thereby reducing component loss and extending service life
Solution Approach 2:
The invention changes the physical state of the shroud material through controlled heating to enable plastic deformation. This parameter change allows the distorted shroud to be reshaped into its original configuration, making the component repairable and eliminating the need for scrapping
3Manufacturing precision
If the bolt hole center displaces from its original design location, then the structural integrity is compromised, but precise realignment is required to restore the original position
Solution Approach 1:
The patent uses a simplified mechanical realignment system consisting of alignment pins and pressing mechanisms applied to the heated material. This substitution of complex precision mechanical systems with thermally-assisted simple mechanical forces enables accurate restoration of the bolt hole center to its original design location, thereby restoring structural integrity
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
Effectively restores the inner shroud to its original design position and dimensions, preventing unnecessary scrapping and ensuring safety by aligning the bolt hole and inner shroud accurately, allowing for the reuse of turbine vane segments.
Implementation Method 1
heating and cooling to achieve plastic deformation and precise alignment
Data Source
AI summary
A method and apparatus for restoring displaced features on a turbine vane segment for a gas turbine engine, such as a vane segment in a low pressure turbine, and more specifically, the inner shroud thereof relative to the outer shroud thereof to meet the original design position and dimensions.