Abrasive Blade Tip Polymer Matrix for Heat-Resistant Bonding
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Solution Overview
Problem
Existing abrasive tips for rotatable blades in turbomachines face challenges with high processing temperatures during manufacturing and heat generation during operation, which can lead to adhesive softening and delamination, especially when combined with metal reinforcements and overcoats, compromising their longevity and performance.
Innovation Solution
The development of an abrasive tip with hard particles in a polymeric matrix material having a glass transition temperature greater than 225°C, combined with fibers and an adhesive bonding, which provides improved heat resistance and reduced heat conductivity to prevent adhesive softening, along with a method of fabrication that includes consolidating the matrix and particles at elevated temperatures and bonding at lower temperatures to ensure durability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If a polymeric matrix material with high glass transition temperature is used in the abrasive tip, then heat resistance is improved and adhesive softening is prevented, but manufacturing complexity increases due to elevated temperature consolidation requirements
Solution Approach 1:
The patent changes the thermal parameter of the matrix material by selecting polymeric materials with high glass transition temperatures (≥225°C), which fundamentally alters the temperature regime during manufacturing and operation, enabling heat resistance while managing manufacturing complexity through controlled thermal processing
Solution Approach 2:
The patent creates a composite material system combining polymeric matrix material with high glass transition temperature, abrasive particles, and optional fibers, where the composite structure provides both heat resistance and manageable manufacturing properties through the synergistic interaction of components
2Strength
If the abrasive tip is bonded to the airfoil section using adhesive, then structural integrity is improved, but heat conductivity increases causing adhesive softening at elevated temperatures
Solution Approach 1:
The polymeric matrix material with high glass transition temperature serves as an intermediary between the abrasive particles and the adhesive bonding layer, providing thermal insulation that protects the adhesive from heat while maintaining structural integrity of the abrasive tip assembly
Solution Approach 2:
The patent changes the thermal parameters of the bonding system by introducing a thermally insulating polymeric matrix layer, which reduces heat transfer to the adhesive and prevents softening while maintaining the structural strength of the joint
3Strength
If metal reinforcements and overcoats are added to the blade, then strength and durability are improved, but heat generation increases leading to adhesive delamination
Solution Approach 1:
The polymeric matrix material with high glass transition temperature acts as a thermal barrier and intermediary layer between the metal reinforcements/overcoats and the adhesive bonding, absorbing and dissipating heat to prevent thermal damage to the adhesive and eliminate delamination
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 solution enhances the abrasive tip's temperature resistance, maintains particle retention, and reduces heat transfer to adhesives, thereby improving the longevity and performance of the abrasive tip by maintaining structural integrity and preventing delamination.
Implementation Method 1
The matrix material is a polymeric material that has a glass transition temperature greater than or equal to about 225 degrees C. (437 degrees F.)
Data Source
AI summary
A blade includes an airfoil section extending between leading and trailing edges, first and second opposed sides each joining the leading and trailing edges, and an inner end and a free end. The blade also includes an abrasive tip at the free end of the airfoil section. The abrasive tip includes particles disposed in a matrix material. The matrix material is a polymeric material that has a glass transition temperature greater than or equal to about 225 degrees C. (437 degrees F.). A gas turbine engine and a method of fabricating a blade are also disclosed.