CMC Stator Vane Flange Layout to Cut Flow Obstruction
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Solution Overview
Problem
Existing stator vanes in gas turbine engines face challenges in withstanding very high temperatures due to their exposure to combustion products, and existing mounting methods can cause flow obstruction and delamination.
Innovation Solution
The stator vanes are formed of ceramic matrix composites (CMC) with attachment flanges extending axially and secured using CMC or metal c-clips, which provide additional strength and sealing without obstructing the flow path, and the ply layup design enhances structural integrity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional mounting flanges are used on stator vanes, then the stator vanes can be mounted in the housing, but the flanges extend in the circumferential direction and obstruct the flow path
Solution Approach 1:
The mounting flanges are reoriented from extending in the circumferential direction to extending in the axial direction, changing the spatial dimension of the flange extension. This dimensional change allows the flanges to be positioned without obstructing the circumferential flow path while maintaining mounting functionality.
2Ease of manufacture
If CMC components are formed using traditional ply layup methods, then the components can be manufactured, but the ply structure is vulnerable to delamination under high temperature and stress
Solution Approach 1:
The ply layup structure is optimized with specific fiber orientations (0°, 90°, ±45° layers) at different locations within the CMC component. This local quality variation enhances the ply structure's resistance to delamination in high temperature and stress environments while maintaining manufacturability through controlled fiber placement.
Solution Approach 2:
The stator vane is constructed as a CMC composite material structure with multiple plies of ceramic fibers embedded in a matrix material. This composite structure provides both manufacturability through layer-by-layer fabrication and enhanced stability against delamination through the interlaminar bonding and fiber reinforcement.
3Reliability
If mounting flanges are used to secure stator vanes, then the vanes can be firmly mounted, but the flanges and mounting hardware create leakage paths
Solution Approach 1:
The harmful leakage paths created by traditional mounting flanges and hardware are eliminated by extracting the mounting function from the flow path area. The axial flanges are positioned to secure the vane firmly while being clear of the circumferential flow, separating the mounting function from the flow guidance function to prevent leakage.
Data Source
Figure 1
Figure 2A~5
Figure 3
AI summary
A stator vane (100) formed of CMC has a radially outer platform (104) and a radially inner platform (106) attached to an airfoil (102). There are a pair of flanges (108, 110; 109, 112) on a side of each of the radially inner platform (106) and radially outer platform (104) which is remote from the airfoil (102). A first of the pair of flanges (108, 110; 109, 112) is associated with the suction side of the airfoil (102) and a second of the pair of flanges (108, 110; 109, 112) is associated with the pressure side of the airfoil (102). The flanges (108, 110; 109, 112) extend in a generally axial direction. The first of the pair of flanges (108, 110; 109, 112) extend over at least a majority of the suction side measured between the leading and trailing edge of the airfoil (102) and the second of the pair of flanges (108, 110; 109, 112) extend over at least a majority of the pressure side measured between the leading and trailing edges of the airfoil (102).