CMC Gas Turbine Sensor Bracket Bonding
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Solution Overview
Problem
Implementing ceramic matrix composite (CMC) materials in gas turbine engine components poses challenges due to their high temperature resistance, particularly in integrating sensors without adhesives that are chemically incompatible or prone to dislodging from thermal expansion differences.
Innovation Solution
A gas turbine engine component with a wall formed of CMC, featuring a sensor bracket bonded using CMC or graphite materials, either by laying-up additional ceramic fiber plies during fabrication or applying an over-coating post-fabrication to secure the bracket on the wall, creating a robust attachment that withstands extreme temperatures.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional adhesives are used to attach sensors to CMC components, then the sensor can be mounted, but the adhesive becomes chemically incompatible or dislodges due to thermal expansion differences at high temperatures
Solution Approach 1:
The bracket and the CMC component wall are made from the same CMC material, ensuring identical thermal expansion properties and chemical compatibility. This homogeneity eliminates the thermal expansion mismatch problem that causes traditional adhesive failures, allowing the sensor to remain securely attached at high temperatures.
Solution Approach 2:
The bracket is integrated directly into the CMC component wall through a unified material structure, merging what would traditionally be separate parts (component and mounting bracket) into a single homogeneous CMC structure. This integration eliminates the need for incompatible adhesives entirely.
2Reliability
If CMC material is used to form the bracket, then thermal compatibility is achieved, but the manufacturing process becomes more complex
Solution Approach 1:
The manufacturing process is segmented into two phases: first, the CMC component wall is fabricated; second, additional ceramic fiber plies are applied and consolidated to form the integrated bracket. This segmentation allows each phase to be optimized independently while maintaining overall process feasibility.
Solution Approach 2:
The bracket structure is prepared in advance by laying up additional ceramic fiber plies during the component fabrication process, before final consolidation. This preliminary action ensures the bracket geometry is established early, simplifying subsequent manufacturing steps.
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 solution provides a robust and durable attachment for sensors, eliminating the need for adhesives and reducing maintenance, while ensuring the bracket remains securely attached even at high temperatures, enhancing the component's operational reliability.
Implementation Method 1
the bracket is formed of a material selected from the group consisting of the CMC, graphite, and combinations thereof... eliminating the need for adhesives that are chemically incompatible or prone to dislodging from thermal expansion differences
Implementation Method 2
The ceramic matrix bonds the bracket on the wall
Implementation Method 3
consolidating the ceramic fiber plies in a ceramic matrix composite (CMC)
Data Source
AI summary
A gas turbine engine component includes a wall that is formed of a ceramic matrix composite (CMC) that has ceramic fiber plies disposed in a ceramic matrix. The component has a sensor section in which a bracket is bonded on the wall for holding a sensor. The bracket is formed of a material selected from the group consisting of the CMC, graphite, and combinations thereof.