CMC Turbine Components Using Non-Ply Ceramic Inserts
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Solution Overview
Problem
Existing methods for manufacturing ceramic matrix composite (CMC) turbine engine components struggle to produce features with thicknesses less than 0.021 inches and small radii, leading to defects and compromised mechanical properties due to the limitations of standard prepreg ply thickness and handling difficulties.
Innovation Solution
The use of non-ply ceramic inserts in combination with prepreg plies allows for the creation of CMC components with fine features, replacing multiple small prepreg plies with discontinuously reinforced composite inserts to achieve isotropic properties and simplify the manufacturing process, enabling the formation of thin sections and small radii without compromising mechanical integrity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If standard prepreg plies are used to manufacture CMC components, then structural integrity is maintained, but the minimum achievable thickness is about 0.030 inch which is too thick for small turbine engines
Solution Approach 1:
The patent segments the component into multiple regions with different thickness requirements and uses multiple ply orientations (0°, ±45°, 90°) in each region to achieve the desired thickness profile. This allows thin sections (0.015-0.021 inch) to be manufactured while maintaining structural integrity through the layered composite structure.
Solution Approach 2:
The patent applies different ply configurations to different regions of the component. Thin-section regions use specific ply orientations and counts to achieve the required thickness, while thicker regions use standard ply arrangements. This local differentiation enables manufacturing of features with thicknesses less than 0.030 inch while maintaining ease of manufacture through standardized local patterns.
2Manufacturing precision
If multiple small prepreg plies are cut and inserted to fit contour changes, then shape accuracy is improved, but the lay-up operations become time-consuming and complex
Solution Approach 1:
The patent uses computer-aided design and analysis to pre-determine the optimal ply orientations and configurations before manufacturing. This preliminary planning allows for automated or semi-automated lay-up processes, significantly reducing the time required for manual cutting and inserting of multiple small plies while maintaining accurate contour geometry.
3Manufacturing precision
If plies of different shapes are custom cut to fit contour changes, then shape accuracy is improved, but the design and lay-up become more complex with non-isotropic mechanical properties
Solution Approach 1:
The patent employs a universal ply orientation system (0°, ±45°, 90°) that can be applied across different component regions and contour types. This standardized approach simplifies the lay-up scheme by using the same basic building blocks in different configurations, reducing design complexity while maintaining shape accuracy through computational modeling and optimization.
Data Source
AI summary
A method for forming a ceramic matrix composite (CMC) component for gas turbine engines. The method contemplates replacing a plurality of plies with insert material. The insert material can be partially cured or pre-cured and applied in place of a plurality of small plies or it may be inserted into cavities of a component in the form of a paste or a ply. The insert material is isotropic, being formed of a combination of matrix material and chopped fibers, tow, cut plies or combinations thereof. The use of the insert material allows for features such as thin edges (650) with thicknesses of less than about 0.030 inches and small radii such as found in corners (680, 710). The CMC components of the present invention replace small ply inserts cut to size to fit into areas of contour change or thickness change, and replace the small ply inserts with a fabricated single piece discontinuously reinforced composite insert, resulting in fewer defects, such as wrinkles, and better dimensional control.