Ceramic Matrix Composite Joints for Gas Turbine Engines
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Solution Overview
Problem
The manufacture and assembly of ceramic matrix composite materials for gas turbine engines face challenges due to their unique characteristics, such as strength and flexibility, which affect mounting, joining, and assembling processes.
Innovation Solution
The use of joints between segments that include inserts received in grooves or slots, bonded via a braze layer or co-infiltrated with the matrix material, along with interlocking fingers and lap joints with fasteners, to securely couple ceramic matrix composite segments in gas turbine engines.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If ceramic matrix composite materials are used in gas turbine engine components, then temperature resistance is improved, but manufacturing and assembly difficulty increases
Solution Approach 1:
The ceramic matrix composite component is divided into multiple segments that can be manufactured separately and then assembled using specialized joints. This segmentation allows each segment to be manufactured with controlled complexity while the final assembly achieves the required temperature resistance and structural integrity.
Solution Approach 2:
The patent employs ceramic matrix composite materials with specific fiber-matrix combinations to achieve both high temperature resistance and improved manufacturability. The composite structure allows for flexible joining methods including braze layers and co-infiltration techniques that are specifically suited to ceramic materials.
2Strength
If inserts are used in grooves to join segments, then joint strength is improved, but device complexity increases
Solution Approach 1:
The insert is nested within grooves formed in the ceramic segments, creating a layered joint structure. The insert fits precisely within the groove geometry, providing mechanical interlocking while the braze layer or matrix material fills the remaining space to create a monolithic appearance, thus strengthening the joint without excessive external complexity.
Solution Approach 2:
The insert acts as an intermediary element between adjacent ceramic segments, providing a transition zone that distributes stresses and enhances bond strength. This intermediary component facilitates the joining process by creating a controlled interface that is easier to manufacture and inspect than direct segment-to-segment bonding.
3Manufacturing precision
If co-infiltration is used to integrally couple segments, then manufacturing precision is improved, but process complexity increases
Solution Approach 1:
The segments and insert are co-infiltrated with matrix material in a single integrated process, merging multiple manufacturing steps into one operation. This simultaneous infiltration ensures precise alignment and intimate contact between segments while the matrix material flows into all interfaces, creating an integral coupling without requiring separate bonding operations.
Solution Approach 2:
The segments and insert are pre-assembled in their final configuration with precise positioning before the co-infiltration process. This preliminary arrangement ensures that when the matrix material is introduced, all components are already in their correct positions, achieving high manufacturing precision while the infiltration process itself remains relatively simple.
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
These solutions enhance the strength and durability of ceramic matrix composite assemblies, improving their ability to withstand operational loads and maintain structural integrity in high-temperature environments.
Implementation Method 1
The inserts may be bonded to the segments via a braze layer or other suitable bond.
Implementation Method 2
the inserts may be co-infiltrated with matrix material along with the segments to integrally couple the assembly
Data Source
AI summary
An assembly for a gas turbine engine includes ceramic material containing (i.e. ceramic matrix composite) segments and joints that couple the segments together.