Gas Turbine Airfoil Insulating Layer and Rib Configuration
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Solution Overview
Problem
Design and manufacture of vanes and blades in gas turbine engines using composite materials are challenging due to the required geometry and strength, especially when dealing with high temperatures and the need for effective cooling.
Innovation Solution
The use of a ceramic matrix composite skin with a reinforcement rib and an insulating layer, where the insulating layer is chemically bonded to the reinforcement rib but not the skin, to thermally insulate the rib from internal cavity temperatures while allowing the skin to be exposed and cooled by air flow, with metallic support spars to secure the insulating layer and manage thermal stresses.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If the reinforcement rib is made from ceramic matrix composite material to withstand high temperatures, then the temperature resistance is improved, but the thermal stress and structural integrity deteriorate due to direct exposure to internal cavity temperatures
Solution Approach 1:
An insulating layer is introduced as an intermediary between the reinforcement rib and the internal cavity. This layer has lower thermal conductivity than the ceramic matrix composite rib material, reducing heat transfer to the rib while maintaining structural integrity and minimizing thermal stress.
2Temperature
If the insulating layer engages both the skin and the reinforcement rib, then the thermal insulation is improved, but the cooling efficiency deteriorates because the skin becomes isolated from cooling air flow
Solution Approach 1:
The insulating layer is selectively applied only to the reinforcement rib, not the skin. This localized insulation approach allows the skin to remain exposed to cooling air flow for efficient heat dissipation, while the rib receives thermal protection where needed.
3Ease of manufacture
If the insulating layer is not secured to prevent movement, then the manufacturing complexity is reduced, but the reliability deteriorates due to potential displacement under thermal and mechanical loads
Solution Approach 1:
Chemical bonding replaces mechanical fastening methods to secure the insulating layer to the reinforcement rib. This approach maintains position stability under thermal and mechanical loads while avoiding complex mechanical attachment systems.
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 configuration enhances the thermal insulation and structural integrity of the airfoil, reducing thermal stress and maintaining the skin's temperature exposure while effectively dissipating heat through cooling air flow, thus improving the durability and performance of the airfoil in high-temperature environments.
Implementation Method 1
The insulating layer engages at least one side of the ceramic matrix composite reinforcement rib to thermally insulate the ceramic matrix composite reinforcement rib from temperatures in the internal cavity
Implementation Method 2
The ceramic matrix composite skin is shaped to define an internal cavity between the pressure side and the suction side of the airfoil sized to carry a cooling air flow
Data Source
AI summary
An airfoil adapted for use in a gas turbine engine is disclosed. The airfoil may include components made from ceramic materials. The airfoil may include insulating material to thermally isolate portions of the airfoil.