Ceramic Airfoil Vane with Metallic Spar for Gas Turbine
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Solution Overview
Problem
Design and manufacture of vanes and blades for gas turbine engines from composite materials are challenging due to complex geometry and strength requirements, particularly in withstanding high temperatures and transferring aerodynamic loads effectively.
Innovation Solution
A vane assembly comprising a ceramic-containing airfoil sandwiched between metallic inner and outer platforms, with a metallic reinforcement spar extending through a hollow core to transfer aerodynamic loads to the platforms, and optionally coupled to a turbine case, allowing for efficient load distribution and thermal management.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If composite materials are used for airfoils to withstand high temperatures, then thermal resistance is improved, but manufacturing complexity and structural strength requirements worsen
Solution Approach 1:
The patent employs ceramic matrix composite materials for the airfoil section to withstand high temperatures, while using metallic materials for the platforms and spar. This composite approach allows the airfoil to achieve high-temperature resistance while the metallic components handle structural strength and manufacturing considerations.
Solution Approach 2:
The vane assembly is divided into distinct segments: a ceramic-containing airfoil section for thermal resistance, metallic platforms for structural support, and a reinforcement spar for aerodynamic load transfer. This segmentation allows each component to be optimized for its specific function while simplifying manufacturing compared to monolithic composite structures.
2Temperature
If ceramic-containing airfoil is used to withstand high temperatures, then thermal durability is improved, but aerodynamic load transfer capability worsens
Solution Approach 1:
A reinforcement spar made from metallic material serves as an intermediary element that transfers aerodynamic loads from the ceramic-containing airfoil to the metallic platforms. The spar engages with the airfoil at multiple points, effectively bridging the thermal resistance advantage of ceramics with the strength requirements for load transfer.
Solution Approach 2:
The hybrid composite structure combines ceramic materials for the airfoil (providing thermal durability) with metallic materials for the spar and platforms (providing strength for load transfer). This composite approach resolves the contradiction by assigning different materials to different functional requirements within the same assembly.
3Productivity
If complex geometry is used for composite vanes and blades, then aerodynamic performance is improved, but manufacturing difficulty worsens
Solution Approach 1:
The vane assembly is segmented into separately manufacturable components (airfoil, platforms, spar) that can be produced using appropriate processes for each material type, then assembled together. This segmentation reduces manufacturing difficulty compared to producing complex composite geometries as single integrated pieces.
Solution Approach 2:
The reinforcement spar is positioned within the hollow core of the airfoil, creating a nested structure. This nesting arrangement allows complex aerodynamic geometries to be achieved while maintaining manufacturing feasibility, as the spar can be inserted after airfoil formation and the hollow core provides natural load distribution.
Data Source
AI summary
A vane assembly for a gas turbine engine is disclosed in this paper. The vane assembly includes an inner platform, an outer platform, and a ceramic-containing airfoil. The ceramic-containing airfoil extends between the inner platform and the outer platform. A reinforcement spar extends between the inner platform and the outer platform through a hollow core of the ceramic-containing airfoil.