Ceramic Matrix Composite Blade Integral Platform Fabrication
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current methods for forming ceramic matrix composite (CMC) blades fail to create an integral platform structure, leading to performance issues and disengagement of platform structures from airfoils, resulting in inadequate sealing and strength.
Innovation Solution
A method involving laying up fibrous ceramic plies in specific arrangements to form an airfoil, dovetail, and integral platform as a unitary preform, followed by rigidization and densification to create a ceramic matrix composite blade with a substantially continuous co-rigidized matrix phase, using a tool with configurable layup surfaces for efficient fabrication.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If current methods for forming CMC blades are used, then blade production is achieved, but integral platform structure cannot be formed leading to disengagement and inadequate sealing
Solution Approach 1:
The patent merges the platform structure formation with the airfoil blade formation into a single integral structure. By using a unified mold that forms both the airfoil and platform simultaneously from the same CMC preform, the invention eliminates the disengagement issues between separate platform structures and airfoils, achieving reliable sealing while maintaining manufacturability through the integrated forming process
2Strength
If separate platform structures are used, then manufacturing is simplified, but structural integrity and strength are compromised
Solution Approach 1:
The invention combines the platform and airfoil into a single integral CMC structure formed from one continuous preform. This merging eliminates weak interfaces between separate components, achieving superior structural integrity. The unified mold design and simultaneous forming process manage the manufacturing complexity while delivering enhanced blade strength and reliability
3Reliability
If conventional sealing hardware designs are used, then compatibility is maintained, but performance with integral platforms is inadequate
Solution Approach 1:
The patent applies local quality by creating a seamlessly integrated platform structure with continuous CMC material that provides enhanced sealing surfaces. The integral design maintains compatibility with conventional sealing hardware while locally optimizing the platform geometry and surface characteristics to improve sealing performance beyond what separate platform structures could achieve
Data Source
AI summary
A method of making a ceramic matrix composite blade includes laying up at least one ply of the plurality of fibrous ceramic plies in a preselected arrangement to form an airfoil and dovetail preform, laying up at least one additional ply of the plurality of fibrous ceramic plies on the airfoil and dovetail preform in a second preselected arrangement to form an integral platform as part of the non-rigidized blade preform, rigidizing the blade preform to form a rigidized blade preform, and densifying the rigidized blade preform to form a ceramic matrix composite blade having an integral platform structure. A tool for making the ceramic matrix composite blade and a ceramic matrix composite blade are also disclosed.