Weld Configuration for Gas Turbine Float Assembly Stress Reduction
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Solution Overview
Problem
Existing weld configurations in gas turbine engines, such as those for float assemblies, often experience stress concentration at the weld root, which can lead to potential failure and reduced reliability.
Innovation Solution
A novel weld configuration featuring a guide with a stand-up and shelf, where a cover is welded perpendicularly, creating a cavity adjacent to the weld joint, thereby distributing stress and reducing concentration at the weld's backside.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a conventional weld configuration is used, then the manufacturing process is simple, but stress concentration occurs at the weld root leading to potential failure
Solution Approach 1:
The weld configuration transitions from a conventional planar joint to a three-dimensional structure by introducing a cavity space adjacent to the weld root. This dimensional change allows stress to be distributed throughout the cavity volume rather than concentrating at a single point, thereby improving weld joint reliability while maintaining manufacturing simplicity
Solution Approach 2:
The cavity acts as an intermediary space between the weld joint and the surrounding structure. This intermediate region captures weld spatter and provides a stress-distributing volume that prevents direct stress concentration at the weld root, enhancing reliability without significantly increasing device complexity
2Stress or pressure
If a weld configuration without cavity is used, then the structure is compact, but stress concentrates at the weld root
Solution Approach 1:
The cavity is introduced locally at the weld root region rather than throughout the entire float assembly. This localized modification provides stress distribution benefits specifically where needed at the weld joint, while maintaining the overall compactness of the float assembly structure
Solution Approach 2:
The cavity creates a three-dimensional stress distribution zone adjacent to the weld joint, allowing stresses to be dispersed in multiple directions and volumes rather than concentrating in a single plane. This dimensional approach improves stress distribution while minimizing volume increase
3Reliability
If the cover is welded directly adjacent to the shelf, then the structure is simplified, but stress concentration occurs at the weld root
Solution Approach 1:
The cavity serves as an intermediary space positioned between the weld joint and the shelf structure. This intermediate region captures weld spatter that would otherwise concentrate at the weld root, and provides a volume for stress distribution, thereby improving float assembly durability while maintaining a relatively simple weld joint configuration
Solution Approach 2:
The harmful effect of stress concentration and weld spatter is extracted from the critical weld root area by providing a cavity space that captures and isolates these stressors. This separation removes the concentration point from the load-bearing path, improving durability without significantly complicating the weld joint configuration
Data Source
AI summary
A float assembly according to an example of the present disclosure includes a guide extending in a first direction that has a stand-up and a shelf. A cover is oriented in a second direction substantially perpendicular to the first direction and welded to the stand-up at a weld joint. An undersurface of the cover abuts the shelf, and the abutment begins at a first distance in the second direction from the weld joint and ends at a second distance in the second direction from the weld joint.