CMC Gas Turbine Blade Fabrication via Segmented Autoclave Curing
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Solution Overview
Problem
The compaction of ceramic matrix composite (CMC) materials in three dimensions for gas turbine engine components, such as rotor blades, is challenging due to the varying orientations of plies, which complicates the processing and curing of these components.
Innovation Solution
A method involving multiple processing steps using layup tools and autoclave cycles with specific compaction directions to form and cure CMC components, allowing for the fabrication of turbine rotor blades with plies oriented in three dimensions by separating the processing of different portions of the blade, such as airfoil, dovetail, and platform plies from angel wing and flowpath plies, optimizing compaction and reducing tooling complexity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If multiple plies with different orientations are processed in a single autoclave cycle, then the structural integrity of the three-dimensional CMC blade is maintained, but the processing complexity and tooling requirements increase significantly
Solution Approach 1:
The blade is divided into multiple segments corresponding to different ply orientations (e.g., radial plies, tangential plies, axial plies). Each segment is processed separately in its own autoclave cycle with optimized compaction direction, then assembled into the final three-dimensional structure. This segmentation allows simple tooling for each segment while achieving complex overall geometry.
Solution Approach 2:
The processing approach transitions from attempting to compact all plies simultaneously in three dimensions to processing plies in sequential two-dimensional layers. Each autoclave cycle compacts plies in a single plane with a defined compaction direction, building the three-dimensional structure through multiple stacked layers processed in sequence.
2Ease of manufacture
If all plies are compacted in a single processing step, then the manufacturing process is simplified, but the compaction efficiency and quality of three-dimensional ply structures deteriorate
Solution Approach 1:
The manufacturing process is segmented into multiple autoclave cycles, each handling a specific set of plies with consistent orientation. This segmentation improves compaction efficiency by ensuring uniform pressure distribution across each ply set, while the cumulative effect of multiple cycles achieves the complete blade fabrication.
Solution Approach 2:
Plies are pre-oriented and pre-positioned in their correct spatial arrangements before autoclave processing. This preliminary action ensures that when compaction is applied, the plies are already in their final three-dimensional configuration, eliminating the need for complex real-time repositioning during compaction and improving overall processing efficiency.
3Strength
If plies are oriented in three dimensions with varying directions, then the structural performance of the turbine blade is enhanced, but the difficulty of compaction and curing increases
Solution Approach 1:
The three-dimensional ply structure is segmented into multiple two-dimensional ply sets, each with uniform orientation within its plane. By processing each segment separately with compaction applied in the appropriate direction for that segment's ply orientation, the manufacturing difficulty is reduced while maintaining the overall three-dimensional structural performance through proper segmentation and assembly.
Solution Approach 2:
Each segment of the blade is processed with compaction parameters optimized for its specific local ply orientation. For example, radially oriented plies receive compaction from the radial direction, while tangential plies receive compaction from the tangential direction. This local optimization of processing parameters maintains ease of manufacture for each segment while achieving high structural performance in the final assembled blade.
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 compaction and curing efficiency of CMC components, reducing processing time and tooling complexity, while maintaining structural integrity and high-temperature resistance, enabling the production of robust and efficient gas turbine engine blades.
Implementation Method 1
The plurality of plies may be processed in an autoclave to compact and cure the plies to form the turbine rotor blade
Implementation Method 2
given an ability for CMC materials to withstand relatively extreme temperatures
Data Source
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AI summary
Methods (1000) for fabricating a component of a gas turbine engine are provided. In one embodiment, the method (1000) includes molding (1002) a CMC material to form a first portion of the gas turbine engine component, processing (1006) the first portion to form a first assembly (A1), preparing (1008) the first assembly and a second portion of the gas turbine engine component for processing, and processing (1010) the first assembly and second portion to form a second assembly (A2). In another embodiment, the method includes processing a first plurality of CMC plies to form a first assembly (A1); positioning the first assembly (A1) and a second plurality of CMC plies on a tool for processing, the first assembly (A1) defining a first plane, the second plurality of plies defining a second plane, wherein the second plane is perpendicular to the first plane; and processing the first assembly and the second plurality of plies to form a second assembly (A2).