Additive Manufacturing Aircraft Turbomachine Vane Support Removal

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Solution Overview

Problem

In additive manufacturing of aircraft turbomachine vanes, temporary support members are needed to prevent material subsidence during production, but their removal poses challenges due to lack of rigidity and precision, risking deformation and damage.

Innovation Solution

The method involves producing temporary support members with recesses during laser fusion on powder beds, allowing for easy removal using a tool that engages the recesses and pivots perpendicular to the edges, stiffening the members and simplifying their shape for easier handling.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If temporary support members are used to prevent material subsidence during additive manufacturing, then manufacturing reliability is improved, but the support members lack rigidity and are difficult to remove without deforming the vanes

Engineering Contradiction:

Improvemanufacturing reliabilityVSAvoidsupport member rigidity

Core Design Contradiction:

ReliabilityVSStrength

Solution Approach 1:

The support member is segmented into a body portion and a removal portion with different material properties. The body portion provides the necessary rigidity and support function, while the removal portion is designed with lower melting point or different material characteristics that allow easy removal after manufacturing, thus resolving the contradiction between needing rigidity during manufacturing and ease of removal afterward

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Different portions of the support member have different local qualities - the body portion is designed with high rigidity to prevent material subsidence during additive manufacturing, while the removal portion is designed with specific material properties that facilitate easy removal. This local differentiation allows the support member to fulfill both contradictory requirements at different locations and times

Inventive Principle:

Principle #3Local quality

2Ease of operation

If a gripper is used to remove support members, then removal operation is possible, but the operator's gesture is not precise and the support member may deform under the applied force

Engineering Contradiction:

Improveremoval operation easeVSAvoidvane geometry precision

Core Design Contradiction:

Ease of operationVSManufacturing precision

Solution Approach 1:

The removal portion is extracted as a separate functional element from the support member body. This extracted portion is specifically designed to be easily removed after manufacturing, allowing the main body to maintain its structural integrity and the vane geometry precision while enabling simple removal operations

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The removal portion is designed as a disposable element that serves its purpose during manufacturing and then is easily removed or discarded. This disposable design allows for simple removal operations without risking deformation of the permanent vane structure, as the removal portion is intended to be temporary and sacrificial

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

3Ease of operation

If the support member shape is simplified for easier removal, then ease of operation is improved, but the member may lack sufficient stiffness

Engineering Contradiction:

Improveremoval operation easeVSAvoidsupport member stiffness

Core Design Contradiction:

Ease of operationVSStrength

Solution Approach 1:

The support member is divided into a body portion with complex geometry for stiffness and a simplified removal portion for ease of removal. This segmentation allows the body to maintain the necessary stiffness while the removal portion is designed for operational simplicity, resolving the contradiction between structural requirements and ease of removal

Inventive Principle:

Principle #1Segmentation

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 enhances the rigidity of support members, facilitates faster and less constraining removal, reducing the risk of deformation and operator error, while also potentially reducing powder consumption and melting time.

Implementation Method 1

additive manufacturing step by laser fusion on powder beds of the vane

Methodology Applied

Scientific EffectLaser fusion: Laser Beam Welding

Data Source

PatentUS11485073B2Method for creating an aircraft turbomachine vane using additive manufacturing

Publication Date: 2022.11.01 SAFRAN AIRCRAFT ENGINES SAS

AI summary

Methods for creating an aircraft turbomachine vane using additive manufacturing include additively manufacturing a vane on a bed of powder using selective laser melting, the additive manufacturing being performed on a support plate so that first or second circumferential edges are manufactured first directly on the support plate, at least one temporary support member being produced simultaneously with the first or second edges. The methods also include removing the temporary support member by breaking its connection with the leading or trailing edge with a tool that is engaged in at least one recess thereof.