3D Woven Composite Turbine Component for Lower-Cost Assembly
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Solution Overview
Problem
Traditional two-dimensional layup designs for composite gas turbine engine components face challenges in manufacturing, including high labor and material costs, assembly complexity, and limited interlaminar strength.
Innovation Solution
The use of three-dimensional woven fabrics and preforms, combined with resin transfer molding and curing processes, to create composite components with enhanced interlaminar strength and efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If traditional two-dimensional layup designs are used for composite components, then manufacturing process is simpler, but interlaminar strength is limited and assembly complexity increases
Solution Approach 1:
The patent transitions from traditional two-dimensional layup designs to three-dimensional woven fabric preforms. This dimensional change enables fibers to be oriented in multiple directions (including through-thickness), significantly improving interlaminar strength while reducing the need for complex assembly operations.
Solution Approach 2:
The patent combines multiple functions into the preform assembly process. The three-dimensional woven fabric preforms are designed to be self-aligning and self-positioning during resin transfer molding, merging the functions of structural support, alignment, and reinforcement into a single integrated component that reduces assembly complexity.
2Ease of manufacture
If traditional two-dimensional layup designs are used, then material usage is simpler, but manufacturing costs increase due to labor and assembly requirements
Solution Approach 1:
The patent employs pre-formed three-dimensional woven fabric preforms that are prepared in advance with the correct geometry, fiber orientation, and structural configuration. This preliminary action eliminates the need for complex on-site assembly operations, reducing labor costs and improving manufacturing efficiency.
Solution Approach 2:
The three-dimensional woven fabric preforms are designed to be self-aligning and self-positioning during the resin transfer molding process. This self-service capability eliminates the need for complex alignment procedures and reduces labor requirements, thereby lowering manufacturing costs and improving productivity.
3Strength
If three-dimensional woven fabrics and preforms are used, then interlaminar strength and structural integrity are improved, but manufacturing process complexity increases
Solution Approach 1:
The patent changes the key parameter of fiber architecture from two-dimensional to three-dimensional woven structures. This parameter change enables superior interlaminar strength and structural integrity while the preform design simplifies the manufacturing process by pre-establishing the complex fiber geometry, reducing in-process complexity.
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 reduces manufacturing costs and complexity while improving the structural integrity and performance of composite components in gas turbine engines.
Implementation Method 1
resin transfer molding and curing processes
Implementation Method 2
resin transfer molding and curing processes
Data Source
AI summary
A method of manufacturing a composite component having an outer shell, an inner hub, and a plurality of struts connecting the outer shell and the inner hub. An outer shell hoop preform and an inner hub hoop preform are woven and installed on a mold tooling structure, a plurality of outer shell pi-joint members are integrally woven to the outer shell hoop preform, and a plurality of inner hub pi-joint members are integrally woven to the inner hub hoop preform. A plurality of strut preforms are connected between respective ones of the outer shell pi-joint members and the inner hub pi-joint members. A matrix material is injected into the mold tooling structure and a curing process is applied to the mold tooling structure to obtain the composite component.