Turbo Machine Airfoil With Composite Button
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Solution Overview
Problem
Turbo machines, such as steam and gas turbine engines, require improved airfoil assemblies to enhance performance and operability, which existing airfoil designs fail to adequately address in terms of weight reduction and efficiency.
Innovation Solution
The airfoil assembly incorporates a composite material button surrounding the airfoil's end, made from polymer matrix composite materials, extending along the chord from the leading edge to the trailing edge, and a metal-based shaft, formed integrally with the airfoil, to reduce weight and improve thrust-to-weight ratio.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If traditional airfoil assemblies are used, then structural strength is maintained, but weight is excessive
Solution Approach 1:
The button is constructed from composite materials including a polymer matrix composite (PMC) material with continuous fiber reinforcement (such as carbon fiber, glass fiber, or aramid fiber). This composite construction provides high strength-to-weight ratio, maintaining structural strength while significantly reducing the weight of the airfoil assembly compared to traditional solid metal buttons.
2Power
If airfoil assembly weight is reduced, then thrust-to-weight ratio improves, but manufacturing complexity increases
Solution Approach 1:
The button is constructed as a layered composite structure with distinct components: a polymer matrix composite material containing continuous fibers oriented in specific directions. The segmentation of fiber orientations (e.g., 0-degree fibers for spanwise strength, 90-degree fibers for chordwise strength) allows optimized structural performance in different directions while maintaining manufacturability through conventional composite layup techniques.
3Weight of moving object
If composite materials are used in the button, then weight is reduced, but manufacturing precision requirements increase
Solution Approach 1:
The composite button features localized fiber reinforcement strategies: continuous fibers are oriented in specific directions (0-degree, 90-degree, or ±45-degree orientations) depending on the local stress requirements. The fiber reinforcement may be concentrated in specific regions such as the spanwise direction at the tip or chordwise direction, providing enhanced strength where needed while minimizing weight elsewhere. This local quality approach optimizes the balance between weight reduction and manufacturing precision.
Data Source
AI summary
An airfoil assembly for a turbo machine, the airfoil assembly including an airfoil defining a leading edge and a trailing edge, and further defining ends separated along a span of the airfoil; a shaft extended from the end of the airfoil; and a button surrounding at least a portion of the end of the airfoil, the button comprising a composite material.