Ceramic-Coated Fiber Containment Case for Gas Turbine Blades
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Solution Overview
Problem
Existing fan containment systems in gas turbine engines are susceptible to premature failure due to cutting or shearing from sharp objects, leading to reduced shear strength and increased weight and cost when attempting to enhance containment capabilities.
Innovation Solution
The use of ceramic-coated fibers in the containment case, with a higher proportion of coated fibers at critical areas, such as the inner surface, to enhance shear resistance and minimize weight and cost by optimizing the ratio of coated to uncoated fibers throughout the structure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If conventional fibers (graphite, Kevlar) are used in containment systems, then the system provides good tensile strength and energy absorption, but the fibers are susceptible to premature failure by cutting and shearing from sharp objects
Solution Approach 1:
The patent applies composite materials by combining conventional fibers (graphite or Kevlar) with a ceramic coating to create a hybrid material system. The ceramic coating provides cutting and shearing resistance while the underlying fiber provides tensile strength and energy absorption, resolving the contradiction between these two properties.
Solution Approach 2:
The patent changes the surface properties of the fibers by applying a ceramic coating, which fundamentally alters the interaction between the fiber and sharp objects. This parameter change (adding ceramic layer) provides resistance to cutting and shearing without compromising the underlying fiber's tensile properties.
2Reliability
If the thickness of containment system material is increased to avoid fiber cutting, then resistance to sharp objects is improved, but engine weight and cost increase
Solution Approach 1:
The patent applies local quality by providing ceramic coating only on the surface of the fibers rather than increasing the overall thickness of the containment system. This localized protection at the fiber surface provides resistance to sharp objects without adding significant weight, as the ceramic layer is thin but effective at preventing cutting.
Solution Approach 2:
The patent extracts the cutting resistance function from the bulk material and places it on the surface through ceramic coating. This separates the functions of cutting resistance (ceramic coating) and structural support (fiber core), allowing thin-weight design with enhanced protection.
3Strength
If more ceramic coated fibers are used in critical areas, then shear strength is enhanced, but manufacturing complexity increases
Solution Approach 1:
The patent applies preliminary action by pre-coating the fibers with ceramic material before assembling the containment system. This pre-coating process simplifies manufacturing compared to applying ceramic coatings after assembly, as the coating is applied to individual fibers or bundles in a controlled manner before integration into the final structure.
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 ceramic-coated fibers significantly improve the shear strength of the containment case, reducing the likelihood of fiber cutting and fraying, thereby enhancing the containment of blade fragments while maintaining a lightweight and cost-effective design.
Implementation Method 1
each coated fiber comprises a fiber surrounded by a ceramic material such that the ceramic material coats the fiber
Data Source
AI summary
Containment assemblies and methods for forming containment assemblies of gas turbine engines are provided. For example, a containment assembly comprises a containment case including a plurality of coated fibers. Each coated fiber comprises a fiber surrounded by a ceramic material such that the ceramic material coats the fiber. As another example, a containment assembly comprises an inner case and a containment case comprising a plurality of coated fibers. Each coated fiber comprises a fiber surrounded by a ceramic material such that the ceramic material coats the fiber. The containment case includes a greater proportion of the coated fibers at an inner surface of a layer of the containment case than at a location within the containment case that is radially outward from the inner surface. Methods for forming a containment assembly of a gas turbine engine are provided.