CMC Airfoil Cooling Passage Layout to Avoid Trailing Edge Delamination
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Solution Overview
Problem
Implementing ceramic matrix composite (CMC) materials in airfoils faces challenges due to unique stress concentrations and potential delamination at radiused ends, which can weaken the structure and compromise the integrity of the airfoil.
Innovation Solution
The airfoil is designed with a ceramic matrix composite structure featuring a radial tube with a radiused end and a filler element, incorporating cooling passages that bypass the radiused end to avoid stress concentrations, using a layout that includes core and skin fiber plies with strategically positioned inlet and outlet orifices to ensure structural integrity and efficient cooling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If CMC materials are used in airfoils to achieve high temperature resistance, then thermal capability is improved, but delamination and reduced durability occur due to unique stress and thermal conditions
Solution Approach 1:
The airfoil is divided into multiple fiber plies (core fiber plies and skin fiber plies) layered together. The core fiber plies form a radial tube structure while skin fiber plies wrap around them, creating segmented layers that distribute thermal and mechanical stresses to prevent delamination and improve durability while maintaining high temperature resistance
Solution Approach 2:
The airfoil uses a composite structure combining ceramic matrix composite materials with fiber plies in a radial tube configuration. This composite design leverages the high temperature resistance of CMCs while the fiber architecture provides stress distribution and structural integrity, resolving the contradiction between thermal capability and durability
2Temperature
If cooling passages are added to manage thermal conditions, then thermal resistance is improved, but structural complexity increases
Solution Approach 1:
The cooling passages are integrated directly into the existing fiber ply structure rather than being separate additions. The passages utilize the natural geometry of the radial tube and wrapped plies, merging cooling functionality with the structural architecture to minimize added complexity while achieving effective thermal management
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 design enhances the structural integrity of CMC airfoils by preventing delamination and provides effective cooling, ensuring durability and performance under high-temperature conditions.
Implementation Method 1
at least one cooling passage has a first, inlet orifice section that opens to the internal cavity at a location forward of the radiused end and extends through the core fiber plies, and a second, outlet orifice section that extends through the trailing edge
Data Source
AI summary
An airfoil includes an airfoil section that defines a trailing edge region that includes a trailing edge. The airfoil section is formed of a ceramic matrix composite that includes core fiber plies and skin fiber plies. The core fiber plies define a radial tube that has a radiused end in the trailing edge region. The skin fiber plies wrap around the core fiber plies and a filler element in the trailing edge region is aft of the internal cavity and is sandwiched between the skin fiber plies on the pressure side and the skin fiber plies on the suction side. There is at least one cooling passage that includes a first, inlet orifice section that opens to the internal cavity at a location forward of the radiused end and that extends through the core fiber plies, and a second, outlet orifice section that extends through the trailing edge.