Composite Casing Flange Weave for Fan Blade Shock Resistance
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Solution Overview
Problem
Existing gas turbine casings face mechanical integrity issues due to deformation and cracking of flanges during a fan blade out event, as the shock wave generated by the impact exceeds the material's stress limits, leading to potential failure.
Innovation Solution
A fibrous texture with a specific arrangement of carbon and glass fibers in the flanges and structural zones, providing varying stiffness and elongation properties to absorb and distribute mechanical deformations effectively.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the fibrous texture uses uniform high-stiffness carbon fibers throughout the casing, then the retention zone can withstand impact forces, but the flanges become overly rigid and susceptible to shock wave-induced cracking
Solution Approach 1:
The patent applies different fiber compositions to different zones of the casing: the retention zone uses high-stiffness carbon fibers (Young's modulus >290 GPa) to withstand impact forces, while the flanges use lower-stiffness carbon fibers (Young's modulus 150-250 GPa) with higher elongation to absorb shock wave deformations. This local differentiation resolves the contradiction by optimizing each zone for its specific functional requirements.
Solution Approach 2:
The patent employs composite fiber structures combining different types of carbon fibers in specific ratios and arrangements. The flanges contain a mixture of high and low stiffness fibers, while the retention zone uses predominantly high-stiffness fibers. This composite approach allows simultaneous optimization of impact resistance and shock wave tolerance in different structural regions.
2Reliability
If the fibrous texture increases fiber elongation to absorb shock waves, then the flanges can withstand deformation, but the retention zone loses impact resistance
Solution Approach 1:
The patent implements zone-specific fiber selection: the retention zone uses carbon fibers with Young's modulus >290 GPa and elongation 1.2-2% for maximum impact resistance, while the flanges use carbon fibers with Young's modulus 150-250 GPa and elongation 4-6% for shock wave absorption. This localized optimization resolves the contradiction between impact strength and shock wave resistance.
3Reliability
If the fibrous texture uses a gradual transition of fiber types from retention zone to flanges, then stress distribution improves, but manufacturing complexity increases
Solution Approach 1:
The patent divides the fibrous texture into five distinct portions along the longitudinal direction, with each portion having a specific fiber composition. The transition from high-stiffness to low-stiffness fibers occurs through defined segments rather than continuous gradient, reducing manufacturing complexity while maintaining stress distribution benefits. The segmentation allows for practical implementation in industrial weaving processes.
Data Source
AI summary
A fibrous texture having a three-dimensional weave between a plurality of layers of warp strands and a plurality of layers of weft strands. The fibrous texture includes first to fifth portions. The first and fifth portions extend in the lateral direction from the first and second lateral edges, respectively. The first and fifth portions each include warp strands composed of a first type of fiber corresponding to carbon fibers having a Young's modulus greater than 290 GPA and an elongation at break comprised between 1.2% and 2% and warp strands composed of a second type of fiber having a Young's modulus between 150 GPA and 250 GPA and an elongation at break between 4% and 6%.