CMC Engine Airfoil Bonding Structure for Shear Load Transfer
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Joining CMC components, such as airfoil segments in gas turbine engines, poses challenges in accommodating shear forces without using separate mechanical structures and maintaining aerodynamic efficiency, particularly in high-temperature environments.
Innovation Solution
Bonding airfoil segments to end bands within CMC nozzles using a monolithic structure with extensions and mating portions, such as dovetails, to enhance shear loading capacity and reduce bulkiness, thereby improving mechanical load distribution.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If separate mechanical structures are used to join CMC airfoil segments to end bands, then shear loading capacity is improved, but device complexity and aerodynamic efficiency deteriorate
Solution Approach 1:
The patent merges the joining function with the CMC material itself by using a monolithic structure where the airfoil segments and end bands are bonded together as a single integrated component. This eliminates the need for separate mechanical fasteners or joining structures, thereby maintaining shear loading capacity while reducing device complexity and preserving aerodynamic efficiency.
Solution Approach 2:
The patent utilizes CMC (ceramic matrix composite) material properties to create a monolithic structure that inherently provides both structural integrity and shear loading capacity. The composite nature of the CMC material allows for seamless bonding between airfoil segments and end bands, eliminating the need for additional mechanical joining structures.
2Ease of operation
If monolithic structure with extensions is used to join CMC components, then aerodynamic efficiency is improved, but manufacturing complexity increases
Solution Approach 1:
The patent divides the CMC component into separate airfoil segments that can be manufactured independently and then joined through a bonding process. The extensions protruding from the end bands provide alignment and bonding surfaces. This segmentation allows for simplified manufacturing of individual components while achieving the desired aerodynamic efficiency through the monolithic final structure.
3Strength
If extensions and mating portions are used to enhance shear loading capacity, then strength is improved, but volume of component increases
Solution Approach 1:
The patent applies extensions and mating portions only at specific locations where shear loading occurs (at the junction between airfoil segments and end bands), rather than increasing the volume of the entire component. This localized approach enhances shear loading capacity precisely where needed while minimizing the overall volume increase of the CMC component.
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 allows for efficient high-temperature operation of gas turbine engines by effectively distributing mechanical loads and enhancing shear loading capacity without the need for additional mechanical fasteners, leading to improved engine performance and reduced costs.
Implementation Method 1
thermal processing, such as a cure or burn-out to yield a high char residue in the preform
Implementation Method 2
subsequent chemical processing, such as melt-infiltration with silicon, to arrive at a component formed of a CMC material having a desired chemical composition
Data Source
Figure 1
Figure 2
Figure 3
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.