Cup-Shaped CMC Inserts for Load-Bearing Turbine Components
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Solution Overview
Problem
The use of ceramic matrix composites (CMCs) in gas turbine engines faces challenges in forming components that can withstand the high temperatures generated by combustion products, particularly in creating thickened areas that require robust mechanical support.
Innovation Solution
A method involving the formation of a load-bearing insert from multiple fabric layers of ceramic matrix composite, which is densified to create a cup-shaped intermediate insert, and then integrated between radially outer and inner layers to form a final insert, with arch-shaped ends to enhance mechanical resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If ceramic matrix composite fabric layers are used to form turbine components, then temperature resistance is improved, but mechanical strength in thickened areas is insufficient
Solution Approach 1:
The patent uses ceramic matrix composite (CMC) material that combines ceramic fibers embedded in a ceramic matrix, creating a composite structure that provides both high temperature resistance and improved mechanical strength. The CMC material maintains structural integrity at elevated temperatures while providing the necessary mechanical properties for thickened areas in turbine components.
Solution Approach 2:
The patent divides the CMC fabric layers into multiple stacked layers that are compressed together to form the insert. This segmentation allows the material to be formed into complex three-dimensional shapes with thickened areas, enabling localized reinforcement where mechanical strength is most needed while maintaining overall temperature resistance.
2Strength
If multiple fabric layers are compressed to form the insert, then mechanical resistance is improved, but manufacturing complexity increases
Solution Approach 1:
The patent prepares multiple CMC fabric layers in advance and stacks them in the desired configuration before compression. This preliminary arrangement of layers allows the complex three-dimensional insert shape to be formed more efficiently, reducing manufacturing complexity by pre-planning the layer arrangement rather than building the shape step-by-step during compression.
Solution Approach 2:
The patent combines multiple CMC fabric layers into a single compressed insert structure. By merging these layers through compression, the manufacturing process consolidates what would otherwise be separate components into one integrated insert, simplifying assembly and reducing the number of manufacturing steps required while achieving the necessary mechanical resistance.
3Reliability
If the insert is densified to form the final structure, then structural integrity is improved, but production time increases
Solution Approach 1:
The patent applies densification treatment that changes the physical parameters of the CMC insert, specifically increasing its density and reducing porosity. This parameter change enhances structural integrity by eliminating voids and weak points in the material, ensuring the insert can withstand the mechanical stresses of turbine operation while maintaining reliability.
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 method effectively enhances the mechanical resistance of turbine components, allowing them to withstand high operational stresses and temperatures, thereby improving the durability and performance of gas turbine engines.
Implementation Method 1
The intermediate insert member is densified (e.g. to form a final insert)
Data Source
Figure 1
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Figure 4A~4D
AI summary
A method of forming a gas turbine engine component (104) includes the steps of forming a component shape from a plurality of fabric layers (126, 128) of ceramic matrix composite. The component has an outer surface. An insert (124) is formed from a plurality of fabric layers (127, 142, 242) of ceramic matrix composites into a cup-shaped intermediate insert (150). The intermediate insert member (150) is densified. Then a final insert (124) is inserted between radially outer layers (128) and radially inner layers (126) on the outer surface. The method then densifies the component (104). A gas turbine engine component (104) and a gas turbine engine (20) are also disclosed.