Ceramic Matrix Composite Gas Turbine Airfoil
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Solution Overview
Problem
Design and manufacture of gas turbine engine airfoils from composite materials are challenging due to complex geometry and strength requirements, especially when exposed to high temperatures, as existing solutions struggle to effectively manage thermal stress and maintain structural integrity.
Innovation Solution
The airfoil is constructed using a ceramic matrix composite material with an exterior wrap and an interior layer of ceramic-containing reinforcing fibers, which are woven, braided, or knotted, and bonded seamlessly around the axis, incorporating a hollow core that may include ceramic foam for enhanced thermal resistance and structural reinforcement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If composite materials are used for high temperature airfoils, then thermal resistance is improved, but manufacturing complexity increases due to complex geometry and strength requirements
Solution Approach 1:
The airfoil is divided into distinct functional layers: an exterior wrap layer for aerodynamic shape and outer protection, an interior layer with continuous ceramic fibers for core structural strength and thermal resistance, and a hollow core for weight reduction and cooling. This segmentation allows each layer to be optimized independently for its specific function while simplifying the overall manufacturing process.
Solution Approach 2:
The invention uses ceramic matrix composite materials throughout the structure, combining ceramic fibers suspended in a ceramic matrix material. The interior layer specifically employs continuous ceramic fibers arranged in a tube configuration, providing both structural integrity and high temperature resistance. This composite approach enables the airfoil to withstand thermal stresses while maintaining manufacturability through proven ceramic composite processing techniques.
2Strength
If continuous ceramic fibers are used in the interior layer, then structural integrity at high temperature is improved, but fabrication complexity increases
Solution Approach 1:
The continuous ceramic fibers in the interior layer are pre-formed into a tube configuration before being integrated into the airfoil structure. This preliminary formation of the fiber tube allows for controlled placement and orientation of the reinforcement elements, ensuring optimal structural integrity while simplifying the subsequent fabrication steps. The pre-formed tube can be manufactured using standard ceramic fiber processing techniques before being incorporated into the composite airfoil structure.
3Temperature
If a hollow core with ceramic foam is used, then thermal resistance is enhanced, but manufacturing precision requirements increase
Solution Approach 1:
The hollow core is filled with ceramic foam material, which provides excellent thermal resistance due to its porous structure. The ceramic foam acts as an effective thermal insulator while maintaining structural support for the surrounding composite layers. This porous material approach enhances thermal resistance without requiring high manufacturing precision, as the foam can be inserted into the hollow core after the outer layers are formed, allowing for tolerant assembly processes.
Data Source
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AI summary
Stationary vanes and rotating blades of a gas turbine engine are disclosed that include airfoils (112,12) formed from ceramic matrix composite materials. The airfoils (112,12) include at least one layer of ceramic-containing matrix material (61) and ceramic-containing reinforcing fibers (62) suspended in the matrix material (61). A core (130,30) of the airfoils (112,12) is surrounded by the at least one layer of ceramic-containing fiber/matrix material (61).