Closed Metal Fan Blade Sheath for Foreign Object Resistance
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Solution Overview
Problem
Gas turbine engine blades face challenges in resisting damage from foreign object ingestion, such as birds or debris, and require materials that prevent cracking and ensure continued operation or safe shutdown.
Innovation Solution
The design incorporates a pressure side sheath and a suction side sheath that form a continuous wraparound structure with central ribs and cavities, using a structural core for attachment to a rotor hub, and a method of securing these sheaths through welding, which enhances durability and resistance to damage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If titanium alloys and fiber composites are used to construct fan or compressor blades, then resistance to cracking from small debris and foreign objects is improved, but device complexity and manufacturing difficulty increase
Solution Approach 1:
The blade is divided into distinct functional zones: a leading edge portion made of damage-resistant material (titanium alloy or fiber composite) and a trailing edge portion made of different material. This segmentation allows each zone to be optimized for its specific function while reducing overall complexity compared to constructing the entire blade from complex composite structures.
Solution Approach 2:
The blade utilizes composite construction by joining different materials (titanium alloy leading edge with metal trailing edge) to achieve both damage resistance and structural integrity. This composite approach provides the benefits of both materials without requiring the full complexity of fiber composite construction throughout the entire blade.
2Reliability
If a continuous sheath wraparound structure is implemented, then durability and resistance to foreign object ingestion are improved, but manufacturing complexity increases
Solution Approach 1:
The continuous sheath is segmented into a first sheath portion and a second sheath portion that are manufactured separately and then joined together. This allows each portion to be manufactured using simpler processes while the final assembly creates the durable continuous wraparound structure that protects against foreign object ingestion.
Solution Approach 2:
Two separately manufactured sheath portions are joined through welding or other joining methods to form a continuous protective sheath. This merging process combines the advantages of separate manufacturing (ease of production) with the benefits of a continuous structure (durability and foreign object resistance).
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
This configuration enhances the durability and resistance of fan and compressor blades to foreign object ingestion, ensuring continued operation and safe shutdown by forming a robust, impact-resistant structure.
Implementation Method 1
a method of securing these sheaths through welding
Data Source
AI summary
A method for forming a blade for a gas turbine engine may include forming a suction side sheath and a pressure side sheath, a first cavity and a second cavity established on opposed sides of a rib, forming a structural core configured for positioning in an interior section of the blade between the suction side sheath and the pressure side sheath, the structural core including a first core member, a second core member and a root interconnecting the first and second core members, assembling the suction side sheath and the pressure side sheath with the structural core such that the first core member is positioned in the first cavity and such that the second core member is positioned in the second cavity, and securing the suction side sheath to the pressure side sheath to form the blade.