CMC Engine Airfoil Bonding Structure Without Mechanical Fasteners

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Solution Overview

Problem

Challenges in securing CMC components with complex geometries during thermal processing, particularly in gas turbine engines, include the need for additional mechanical fasteners and potential gaps or misalignment of composite plies, which affect load-bearing properties and aerodynamics.

Innovation Solution

A method of forming CMC components by separately heating parts and bonding them with extensions and mating portions, such as dovetails, to create a monolithic structure without mechanical fasteners, enhancing load distribution and shear loading capacity.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If mechanical fasteners are used to secure CMC parts during thermal processing, then the parts can be held in position, but the load-bearing properties and aerodynamic efficiency are reduced due to additional mechanical structures and potential gaps

Engineering Contradiction:

Improvepositioning stabilityVSAvoidload-bearing capacity

Core Design Contradiction:

ReliabilityVSStrength

Solution Approach 1:

The patent replaces mechanical fasteners with a chemical bonding system. A bonding agent is applied to the bonding surface of at least one CMC part, and upon heating during thermal processing, the bonding agent cures to form a strong chemical bond between parts. This substitution eliminates the need for mechanical fasteners, removing gaps and stress concentration points while maintaining secure positioning and significantly improving load-bearing capacity and aerodynamic efficiency.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Reliability

If mechanical fasteners are used to secure CMC parts, then positioning is achieved, but device complexity increases due to additional mechanical structures

Engineering Contradiction:

Improvepositioning stabilityVSAvoidstructural complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent extracts and removes the mechanical fastening system from the CMC component assembly. By using a bonding agent that cures during thermal processing, the invention eliminates mechanical fasteners entirely, simplifying the overall structure and reducing the number of components while maintaining secure bonding between CMC parts.

Inventive Principle:

Principle #2Taking out (Extraction)

3Strength

If CMC parts are bonded during thermal processing, then a monolithic structure is formed improving load distribution, but the manufacturing process becomes more complex

Engineering Contradiction:

Improveload distributionVSAvoidmanufacturing process simplicity

Core Design Contradiction:

StrengthVSEase of manufacture

Solution Approach 1:

The patent merges the bonding process with the thermal processing cycle. The bonding agent is applied to CMC parts before or during thermal processing, and the curing of the bonding agent occurs simultaneously with the heating process. This integration combines two operations into one, eliminating the need for separate bonding and thermal processing steps, thereby simplifying manufacturing while achieving strong chemical bonds that create a monolithic structure with superior load distribution.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The bonding agent is applied to the CMC parts in advance of or during the thermal processing cycle, preparing the bonding interface before the final curing occurs. This preliminary application allows the bonding agent to be in position and ready to cure when heating begins, integrating the bonding action with the thermal processing sequence and simplifying the overall manufacturing process.

Inventive Principle:

Principle #10Preliminary action

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 approach improves the mechanical integrity and aerodynamic efficiency of CMC components by distributing loads effectively and accommodating high temperatures and shear forces, reducing the need for bulky mechanical structures.

Implementation Method 1

the bonding agent cures upon heating to form a strong bond between the CMC parts

Methodology Applied

Scientific EffectCuring: Photopolymerisation

Implementation Method 2

heating the CMC parts and the bonding agent to a curing temperature

Methodology Applied

Scientific EffectHeating: Heating

Data Source

PatentUS20260022075A1Ceramic matrix composite component manufacturing

Publication Date: 2026.01.22 GENERAL ELECTRIC CO

AI summary

A method for manufacturing a ceramic matrix composite (CMC) engine airfoil component includes laying first composite plies to form a part and heating the part to form an intermediate part. The intermediate part includes a first portion bonded to a second portion, and the first portion includes an extension. The method further includes laying second composite plies on the extension, the second composite plies extending from the extension to the second portion, and heating the intermediate part and the second composite plies to form the CMC engine airfoil component.