3D Woven Ceramic Matrix Composite Turbine Blade Preform

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Solution Overview

Problem

Current methods for producing ceramic matrix composite (CMC) turbine engine blades are complex and costly, often resulting in stress concentration at joints and seams that can lead to cracking during extended service.

Innovation Solution

A method involving three-dimensional weaving of elongate fibers to create a unitary woven preform, which is then folded and densified with a ceramic matrix to form a CMC turbine engine blade, eliminating complex joints and seams while being produced at low cost.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If traditional methods with joints and seams are used to produce CMC turbine blades, then manufacturing flexibility is improved, but stress concentration and cracking risk increase during extended service

Engineering Contradiction:

Improvemanufacturing flexibilityVSAvoidstress concentration and cracking resistance

Core Design Contradiction:

Ease of manufactureVSReliability

Solution Approach 1:

The patent merges multiple blade sections (airfoil, platforms, platforms) into a single unitary woven preform structure. The three-dimensional weaving process creates continuous fibers that extend through all regions without interruptions, joints, or seams. This merging eliminates stress concentration points while maintaining manufacturing flexibility through the drapeability of the woven fabric during preform creation.

Inventive Principle:

Principle #5Merging (Combining)

2Adaptability or versatility

If complex multi-piece construction methods are used, then adaptability to different blade designs is improved, but device complexity and production cost increase

Engineering Contradiction:

Improvedesign adaptabilityVSAvoidmanufacturing complexity and cost

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The patent employs a dynamic three-dimensional weaving process that can adapt fiber orientation, density, and distribution in real-time during preform fabrication. The weaving apparatus can adjust parameters to create different blade geometries, platform configurations, and fiber architectures from a single unitary structure, providing design adaptability without requiring complex multi-piece assembly or expensive tooling for each variant.

Inventive Principle:

Principle #15Dynamics

3Reliability

If unitary three-dimensionally woven preforms are used, then stress distribution and durability are improved, but manufacturing speed and productivity may decrease

Engineering Contradiction:

Improvedurability and stress distributionVSAvoidmanufacturing speed

Core Design Contradiction:

ReliabilityVSProductivity

Solution Approach 1:

The patent implements continuous three-dimensional weaving that creates unitary preforms in a single uninterrupted manufacturing process. The continuous fiber reinforcement and uninterrupted weaving action eliminate the need for separate assembly operations, joining steps, and quality inspections between multiple pieces. This continuity maintains high durability through superior stress distribution while actually improving productivity by eliminating intermediate manufacturing steps.

Inventive Principle:

Principle #20Continuity of useful action

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

The method enables the quick and consistent production of CMC turbine engine blades with reduced stress concentration, improving durability and maintaining low production costs.

Implementation Method 1

three-dimensionally weaving elongate ceramic fibers to create a unitary woven preform including continuous warp fibers extending along a first direction, continuous weft fibers extending along a second direction substantially normal to the first direction, and continuous fibers extending in a third direction substantially normal to the first and the second direction

Methodology Applied

Scientific EffectThree-dimensional weaving:

Implementation Method 2

folding the flaps into a plane substantially normal to a plane of the airfoil region to form a shaped woven preform

Methodology Applied

Scientific EffectFolding: Folding

Implementation Method 3

densifying the shaped woven preform with a ceramic matrix to obtain a ceramic matrix composite (CMC) turbine engine blade

Methodology Applied

Scientific EffectDensification: Compression

Data Source

PatentUS10563523B2Method for fabricating a ceramic matrix composite rotor blade

Publication Date: 2020.02.18 ROLLS ROYCE CORP

AI summary

A method for making a turbine engine blade includes three-dimensionally weaving elongate fibers of a material selected from the group consisting of carbon, glass, silica, silicon carbide, silicon nitride, aluminum, aramid, aromatic polyamide, and combinations thereof to create a woven preform including a single piece of woven material. The woven preform includes continuous warp fibers extending along a first direction, continuous weft fibers extending along a second direction substantially normal to the first direction, and continuous fibers extending in a third direction substantially normal to the first and the second directions. The woven preform includes an airfoil region extending along the first direction and an arrangement of flaps extending along the second direction. The flaps are folded into a plane substantially normal to a plane of the airfoil region to form a shaped woven preform. The shaped woven preform is densified with a ceramic matrix.