Ceramic Matrix Composite Inspection and Repair After Impact Damage
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Solution Overview
Problem
Ceramic matrix composite components in gas turbine engines have a relatively low capability when subjected to impact from domestic or foreign object debris, making them less tolerant compared to metallic components, which poses a challenge for operational safety and efficiency.
Innovation Solution
A method is introduced to inspect ceramic matrix composite components for damage, determine the extent of damage, and apply appropriate repair techniques, including direct and indirect repairs, using visual and non-visual inspections, and engine health monitoring systems to ensure the components meet predetermined thresholds and residual severity limits, thereby enabling continued safe operation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If ceramic matrix composite materials are used in gas turbine engine components, then high-temperature resistance is improved, but impact damage tolerance deteriorates
Solution Approach 1:
The patent implements preliminary inspection actions using non-destructive evaluation methods (visual inspection, ultrasonic testing, thermography) to detect impact damage before it progresses to critical levels. This allows early identification of damage in ceramic matrix composite components, enabling preventive maintenance and avoiding catastrophic failures while maintaining the use of high-temperature resistant materials.
Solution Approach 2:
The patent establishes a feedback mechanism through engine health monitoring systems that track the condition of ceramic matrix composite components over time. By continuously monitoring for impact damage and providing feedback on component status, the system enables data-driven decisions about maintenance scheduling and component replacement, balancing the benefits of high-temperature operation with safety considerations.
2Productivity
If ceramic matrix composite components are used in gas turbine engines, then operational efficiency at high temperatures is improved, but safety under impact conditions deteriorates
Solution Approach 1:
The patent implements preliminary damage detection using non-destructive evaluation methods to identify impact damage before it compromises safety. By detecting damage early in the component lifecycle, the system maintains operational efficiency of ceramic matrix composite components while ensuring safety through proactive identification of potential failures.
Solution Approach 2:
The patent establishes continuous monitoring and feedback loops that track component performance and detect anomalies indicating impact damage. This feedback enables real-time or near-real-time assessment of component safety, allowing operators to maintain high operational efficiency while responding promptly to safety concerns.
3Weight of moving object
If ceramic matrix composite materials are used instead of metallic materials, then weight is reduced, but damage tolerance capability deteriorates
Solution Approach 1:
The patent implements preliminary inspection protocols specifically tailored for ceramic matrix composite components to detect impact damage that may occur despite their lighter weight. By establishing routine non-destructive evaluation schedules, the system ensures that weight savings from using ceramic materials are not compromised by undetected damage.
Solution Approach 2:
The patent applies localized inspection methods focused on specific high-risk areas of ceramic matrix composite components where impact damage is most likely to occur. By concentrating inspection resources on critical regions such as leading edges and surfaces exposed to debris, the system effectively monitors damage tolerance in the lightweight components without requiring comprehensive inspection of entire components.
Data Source
AI summary
A method comprises inspecting a ceramic matrix composite component assembled in a gas turbine engine to determine an extent of damage to the ceramic matrix composite component, determining a repair technique to repair the damage to the ceramic matrix composite component based on the extent of damage to the ceramic matrix composite component, and repairing the ceramic matrix composite component using the repair technique.