Ceramic Gas Turbine Attachment Wedge Interface
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Solution Overview
Problem
Gas turbine engine components, particularly those made of ceramic matrix composites, face challenges in withstanding high mechanical loads and ensuring secure attachment under pulling forces, as existing bonding methods may fail to provide sufficient strength and durability.
Innovation Solution
A ceramic attachment system using a wedge-like configuration with angled surfaces and keepers, secured by a transient liquid phase bond, which includes a multilayer metal structure to enhance the bonding strength and accommodate differences in wetting characteristics between ceramic materials, effectively locking the components together under both pulling and shear forces.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If existing bonding methods are used to attach ceramic matrix composite components, then the attachment process is simple, but the bonding strength and durability under high mechanical loads are insufficient
Solution Approach 1:
The patent employs a multilayer bonding structure comprising a first bonding layer and a second bonding layer with different material compositions and properties. The first bonding layer provides strong adhesion to the ceramic matrix composite workpiece, while the second bonding layer provides strength and durability under mechanical loads. This composite bonding structure resolves the contradiction by combining materials with complementary properties to achieve both high bonding strength and structural integrity without excessive complexity.
Solution Approach 2:
The bonding attachment is divided into multiple functional layers, each performing a specific function. The first bonding layer is dedicated to adhesion to the ceramic substrate, while the second bonding layer handles mechanical load bearing. This segmentation allows each layer to be optimized for its specific function, achieving high overall performance without requiring a single overly complex bonding solution.
2Reliability
If a secure attachment structure is implemented to withstand pulling forces, then the reliability under mechanical loads improves, but the manufacturing complexity increases
Solution Approach 1:
The patent incorporates a keepers system that pre-positions and mechanically secures the bonding layers to the ceramic matrix composite workpiece before final bonding completion. The keepers provide preliminary mechanical support and alignment, ensuring the bonding structure can withstand pulling forces during manufacturing and operation. This preliminary mechanical securing action improves reliability without significantly complicating the overall manufacturing process, as the keepers are integrated into the bonding structure.
3Duration of action of stationary object
If a robust bonding structure with multiple layers is used, then the durability under mechanical stresses improves, but the manufacturing process becomes more complex
Solution Approach 1:
The patent applies different material compositions and properties to different regions and layers of the bonding structure. The first bonding layer has properties optimized for adhesion to the specific ceramic matrix composite workpiece surface, while the second bonding layer has properties optimized for withstanding mechanical stresses and environmental conditions. This local differentiation of material qualities achieves high durability without requiring a uniformly complex structure throughout, as each layer is specifically tailored to its functional requirements.
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 solution provides a robust and durable attachment that withstands high pulling loads and mechanical stresses, ensuring the longevity and performance of ceramic matrix composite components in gas turbine engines by combining the wedge interface with a strong bonding material.
Implementation Method 1
secured by a transient liquid phase bond
Data Source
Figure 1
Figure 2~4
AI summary
A gas turbine engine component assembly includes first and second portions, wherein at least one of the first and second portions is a ceramic material. The first portion includes an aperture having a first angled surface. The second portion is disposed within the aperture and includes a second angled surface adjacent to the first angled surface. The first and second angled surfaces lock the first and second portions to one another under a pulling load. A bonding material operatively secures the first and second angled surfaces to one another.