CMC Blade Outer Air Seal Slot Notch for Thermal Stress Relief

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Solution Overview

Problem

Existing ceramic matrix composite (CMC) components in gas turbine engines face issues with localized thermal gradients and material stresses due to feather seal slots, leading to potential local failures.

Innovation Solution

A notch is machined into the CMC blade outer air seal segment to alleviate thermal gradients by removing material subject to localized cooling effects, with dimensions optimized to reduce thermal differences and stress concentrations.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If a feather seal slot is provided in a CMC blade outer air seal assembly, then the seal function is improved, but localized thermal gradients and material stresses increase leading to potential local failures

Engineering Contradiction:
Improveseal functionVSAvoidlocalized thermal gradients and material stresses
Core Design Contradiction:
ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The patent applies local quality by providing thermal barrier material specifically at the radially inner surface of the CMC air seal segment, rather than uniformly throughout. This localized application addresses the specific area where thermal gradients and stresses occur due to the feather seal slot, protecting the critical region without adding unnecessary material elsewhere. The thermal barrier material creates a temperature gradient that reduces thermal stress concentrations at the slot interface.

Inventive Principle:
Principle #3Local quality

Solution Approach 2:

The patent uses composite materials by combining CMC (ceramic matrix composite) for the air seal segment structure with a separate thermal barrier material layer. This composite approach allows the CMC to provide structural integrity and sealing function while the thermal barrier material specifically addresses thermal management concerns. The combination of these two materials with different thermal properties creates a system that simultaneously achieves seal functionality and thermal stress mitigation.

Inventive Principle:
Principle #40Composite materials

2Object-affected harmful factors

If thermal barrier material is applied at the radially inner surface of the CMC air seal segment, then thermal stresses are reduced, but the manufacturing complexity increases

Engineering Contradiction:
Improvethermal stressesVSAvoidmanufacturing complexity
Core Design Contradiction:
Object-affected harmful factorsVSEase of manufacture

Solution Approach 1:

The patent applies preliminary action by pre-forming the thermal barrier material as an integral part of the air seal segment manufacturing process, rather than adding it as a separate post-processing step. The thermal barrier material is incorporated during the CMC fabrication process itself, allowing the layers to be formed together in a single manufacturing cycle. This approach reduces manufacturing complexity compared to applying thermal barrier coating separately after the CMC component is fully fabricated.

Inventive Principle:
Principle #10Preliminary action

Data Source

PatentEP3819477B1Feather seal slot arrangement for a CMC blade outer air seal assembly
Publication Date: 2025.12.24 RTX CORP
  • EP3819477B1 patent drawingFigure 1
  • EP3819477B1 patent drawingFigure 2
  • EP3819477B1 patent drawingFigure 3~4

AI summary

A flow path component includes a base portion (124) that extends between a first circumferential side (C1) and a second circumferential side (C2). A first wall (120) and a second wall (122) extend radially outward from the base portion (124). The first wall (120) is axially spaced from the second wall (122) to form a passage (138) between the first and second walls (120; 122). A slot (160) is formed in the first circumferential side (C1). A notch (172) in the base portion (124) extends in a radial direction from the passage (138) to the slot (160).