Gas Turbine Blade Abrasive Tip With Low-Heat Polymeric Matrix

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Solution Overview

Problem

Existing abrasive tips in gas turbine blades face issues with heat conduction and delamination due to friction, especially when combined with polymeric-based abradable seals, leading to compromised erosion protection and adhesive bond integrity.

Innovation Solution

The abrasive tip is designed with a polymeric matrix containing high glass transition temperature particles and fibers, which provides improved heat resistance and reduced heat conductivity, along with a method of manufacturing that avoids high-temperature processing to maintain adhesive integrity.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If conventional abrasive tips with metallic or ceramic matrices are used, then erosion protection is provided, but heat conduction causes delamination and compromises adhesive bond integrity

Engineering Contradiction:

Improveerosion protectionVSAvoidadhesive bond integrity

Core Design Contradiction:

StrengthVSReliability

Solution Approach 1:

The patent applies composite materials by combining polymeric matrix with high glass transition temperature particles and fibers. This composite structure provides both erosion protection through the hard particles and reduced heat conduction through the polymeric matrix, preventing delamination and maintaining adhesive bond integrity while protecting the blade tip.

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

The patent changes the material parameters by selecting particles with high glass transition temperature and using a polymeric matrix with specific thermal properties. This parameter change reduces heat conduction compared to conventional metallic or ceramic matrices, thereby preventing thermal delamination while maintaining abrasive functionality.

Inventive Principle:

Principle #35Parameter changes

2Reliability

If polymeric-based abradable seals are used, then small clearance is provided, but friction heat causes delamination and compromises erosion protection

Engineering Contradiction:

Improveclearance controlVSAvoidheat-induced delamination

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The patent converts the harmful friction heat generated during seal interaction into a beneficial outcome by using a polymeric matrix with high glass transition temperature that can withstand the heat. The heat that would normally cause delamination is now managed by the thermally resistant matrix, allowing the abrasive tip to maintain both clearance control and erosion protection.

Inventive Principle:

Principle #22Blessing in disguise (Convert harm into benefit)

Solution Approach 2:

The patent changes the thermal parameters of the abrasive tip material by using a polymeric matrix with high glass transition temperature. This parameter change enables the material to resist heat-induced delamination while maintaining the small clearance provided by the polymeric-based abradable seal.

Inventive Principle:

Principle #35Parameter changes

3Ease of manufacture

If high-temperature processing is used during fabrication, then material bonding is achieved, but adhesive integrity is compromised

Engineering Contradiction:

Improvematerial bondingVSAvoidadhesive integrity

Core Design Contradiction:

Ease of manufactureVSReliability

Solution Approach 1:

The patent changes the processing temperature parameters by avoiding high-temperature processing during fabrication. This parameter change preserves adhesive integrity while still achieving material bonding through alternative methods that are compatible with the polymeric matrix and adhesive system.

Inventive Principle:

Principle #35Parameter changes

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 longevity and adhesive bond strength by minimizing heat transfer and delamination, ensuring effective wear protection and erosion resistance.

Implementation Method 1

The abrasive tip is designed with a polymeric matrix containing high glass transition temperature particles and fibers, which provides improved heat resistance and reduced heat conductivity

Methodology Applied

Scientific EffectHeat conduction: Conduction (thermal)

Implementation Method 2

Existing abrasive tips in gas turbine blades face issues with heat conduction and delamination due to friction, especially when combined with polymeric-based abradable seals

Methodology Applied

Scientific EffectFriction: Friction

Data Source

PatentEP3913189B1Gas turbine blade with abrasive tip

Publication Date: 2025.10.22 RTX CORP

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AI summary

A blade (62) includes an airfoil section (64) extending between leading and trailing edges (66, 68), first and second opposed sides (70, 72) each joining the leading and trailing edges (66, 68), and an inner end (74) and a free end (76). The blade (62) also includes an abrasive tip (78) at the free end of the airfoil section (64). The abrasive tip (78) includes particles diposed in a matrix material (84). The matrix material (84) is a polymeric material that has a glass transition temperature greater than or equal to about 225 degrees C (487 degrees F). A gas turbine engine (20) and a method of fabricating a blade (62) are also disclosed.