Interlocking Ceramic Matrix Composite Blade Track Segments

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Solution Overview

Problem

Current blade tracks in gas turbine engines face challenges in withstanding high temperatures and maintaining structural integrity, particularly in high-temperature environments, where existing ceramic matrix composite materials may not provide sufficient interlocking and reinforcement to prevent segment movement and potential leakage.

Innovation Solution

A blade track design utilizing interlocking ceramic matrix composite segments with specific finger and band configurations, including attachment fingers and reinforcement pins, to form a full-hoop structure that blocks movement in multiple directions and enhances structural integrity, using chemical vapor infiltration and slurry-melt infiltration for densification.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Temperature

If ceramic matrix composite materials are used in high-temperature environments, then temperature resistance is improved, but structural integrity and interlocking capability deteriorate

Engineering Contradiction:

Improvetemperature resistanceVSAvoidstructural integrity

Core Design Contradiction:

TemperatureVSStrength

Solution Approach 1:

The blade track is divided into multiple segments that can be assembled together to form a complete track. Each segment includes bands and fingers that interlock with adjacent segments, distributing structural loads and maintaining integrity in high-temperature environments where monolithic structures might fail.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The finger-receiving space design allows fingers from one segment to be received within spaces formed by bands and fingers of adjacent segments. This nested interlocking arrangement provides mechanical reinforcement and maintains structural integrity through thermal expansion and contraction.

Inventive Principle:

Principle #7Nested doll (Nesting)

2Strength

If interlocking segments are used to prevent movement, then structural integrity is improved, but device complexity increases

Engineering Contradiction:

Improvestructural integrityVSAvoidsegment configuration complexity

Core Design Contradiction:

StrengthVSDevice complexity

Solution Approach 1:

The segments are designed with asymmetric finger and band configurations where fingers extend in specific directions and receive corresponding fingers from adjacent segments. This asymmetric interlocking provides strong mechanical bonding while maintaining manufacturing simplicity through standardized segment components.

Inventive Principle:

Principle #4Asymmetry

Solution Approach 2:

Instead of using complex external fasteners or adhesives to join segments, the design inverts the approach by having the segments themselves form interlocking fingers and receiving spaces that mechanically bond adjacent segments together through their own structural elements.

Inventive Principle:

Principle #13The other way round (Inversion)

3Temperature

If dense ceramic matrix composite structure is used, then high-temperature resistance is improved, but thermal expansion matching deteriorates

Engineering Contradiction:

Improvehigh-temperature resistanceVSAvoidthermal expansion matching

Core Design Contradiction:

TemperatureVSStability of the object's composition

Solution Approach 1:

The blade track structure incorporates local variations in density and composition through the interlocking finger and band design. The finger-receiving spaces and interlocking interfaces provide localized compliance that accommodates differential thermal expansion between segments while maintaining overall structural integrity at high temperatures.

Inventive Principle:

Principle #3Local quality

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 interlocking design effectively prevents segment movement and enhances structural integrity, reducing leakage and thermal expansion issues, while the ceramic matrix composite materials provide high-temperature resistance and reduced thermal expansion matching, improving the blade track's performance and reliability.

Implementation Method 1

using chemical vapor infiltration and slurry-melt infiltration for densification

Methodology Applied

Scientific EffectChemical vapor infiltration: Chemical Vapour Deposition

Implementation Method 2

using chemical vapor infiltration and slurry-melt infiltration for densification

Methodology Applied

Scientific EffectSlurry-melt infiltration:

Implementation Method 3

reducing leakage and thermal expansion issues, while the ceramic matrix composite materials provide high-temperature resistance and reduced thermal expansion matching

Methodology Applied

Scientific EffectThermal expansion: Thermal Expansion

Data Source

PatentEP3450699B1Ceramic matrix composite blade track for a gas turbine engine and method of making the same

Publication Date: 2021.02.03 ROLLS ROYCE CORP

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AI summary

A gas turbine engine (10) may comprise a blade track (20, 220, 320) and a method of making the same. The blade track (20, 220, 320) may be constructed of ceramic matrix composite components including segments and joints.