Ceramic Composite Seal Ring for High-Temperature Compressor Wear

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Solution Overview

Problem

Conventional piston seal rings in gas turbine engines suffer from degradation due to high temperature exposure and vibration, leading to limited operational lifespan.

Innovation Solution

A ceramic matrix composite material with unidirectionally aligned fibers within a ceramic matrix is used to create piston seal rings, optionally coated with an interface coating, to enhance durability and resistance to high-temperature environments.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Duration of action of moving object

If conventional piston seal rings made of cobalt-based chromium tungsten alloy are used, then the rings can operate in high-pressure compressor environments, but they suffer from degradation due to high temperature exposure and vibration, leading to limited operational lifespan

Engineering Contradiction:

Improveoperational lifespanVSAvoidresistance to degradation

Core Design Contradiction:

Duration of action of moving objectVSReliability

Solution Approach 1:

The patent applies composite materials by combining ceramic matrix with continuous unidirectionally aligned fibers to create a piston seal ring that maintains structural integrity under high temperature and vibration. The composite structure provides both the durability needed for extended operational lifespan and the resistance to thermal degradation required for reliable performance in high-pressure compressor environments.

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

The patent changes the material parameters by transitioning from a metallic cobalt-based alloy to a ceramic matrix composite with specific fiber alignment. This parameter change enables the material to withstand higher temperatures and mechanical stresses, directly addressing the degradation issues that limited the operational lifespan of conventional seal rings.

Inventive Principle:

Principle #35Parameter changes

2Reliability

If a Cu-Al coating is applied to piston seal rings, then the rings gain initial lubrication protection, but the dry-film lubricant wears away during repeated operational cycles, exposing the coating and leading to eventual degradation of the base alloy material

Engineering Contradiction:

Improveprotection against wear and degradationVSAvoidoperational lifespan

Core Design Contradiction:

ReliabilityVSDuration of action of moving object

Solution Approach 1:

The ceramic matrix composite structure replaces the multi-layer coating system (Cu-Al coating with dry-film lubricant) with an inherently durable ceramic-based material. This eliminates the wear progression problem where lubricant wears away to expose the underlying coating, as the ceramic composite maintains its protective properties throughout the operational lifespan.

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

The patent extracts and eliminates the temporary lubricant layer from the seal ring structure. Instead of applying a dry-film lubricant that wears away over time, the ceramic matrix composite provides continuous protection without requiring a consumable lubricant layer, thereby removing the mechanism that leads to base material degradation.

Inventive Principle:

Principle #2Taking out (Extraction)

3Strength

If ceramic matrix composite material with unidirectionally aligned fibers is used, then durability and resistance to high-temperature environments are enhanced, but the manufacturing process becomes more complex

Engineering Contradiction:

Improvedurability and resistance to high temperatureVSAvoidmanufacturing complexity

Core Design Contradiction:

StrengthVSEase of manufacture

Solution Approach 1:

The manufacturing process is segmented into distinct phases: forming the ceramic matrix, embedding the unidirectionally aligned fibers, and sintering the composite structure. This segmentation allows each step to be optimized independently, making the complex manufacturing process more manageable while achieving the desired high-temperature resistance and durability.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The fibers are unidirectionally aligned and positioned within the ceramic matrix before the final sintering process. This preliminary action ensures the fibers are correctly oriented to provide maximum strength and thermal resistance, allowing the complex composite structure to be manufactured systematically rather than requiring post-processing alignment.

Inventive Principle:

Principle #10Preliminary action

Data Source

PatentUS20250314177A1Ceramic matrix composite parts and methods for their production

Publication Date: 2025.10.09 RTX CORP

AI summary

A ceramic composite sealing ring, high-pressure compressor of a gas turbine engine assembly including a ceramic composite sealing ring and method for making a high-pressure compressor of a gas turbine engine assembly. The ceramic composite material is composed of unidirectional aligned fibers which may be encapsulated by a ceramic matrix. The piston seal ring of the high-pressure compressor of a gas turbine engine assembly is positioned at the interface of the tie shaft and the integrated blade rotor.