CMC Material Testing Load Distribution System
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Solution Overview
Problem
Mechanical testing of ceramic matrix composite (CMC) materials in gas turbine engines faces challenges in applying uniform, repeatable, and predictable test loads due to their irregular shapes and high hardness, which traditional methods struggle to address effectively.
Innovation Solution
A material testing system comprising a load rod, rocker arm, and load distribution system with sliding rods and shoes equipped with ball bearings forming an equilateral triangle, allowing the load to be distributed equally and predictably across the test article's surface, even when encountering different heights, by pivoting the rocker arm and articulating the shoes to maintain a consistent center of loading.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional loading methods are used on CMC test articles with irregular shapes, then the testing process is simple, but the load distribution is non-uniform and unpredictable
Solution Approach 1:
The loading system is segmented into multiple independent loading points (first and second load applicators) that can be individually adjusted. Each loading point has its own articulation mechanism, allowing independent positioning to accommodate irregular test article geometries while maintaining uniform load distribution across multiple contact points
Solution Approach 2:
The system employs dynamic articulation mechanisms at each loading point that allow real-time adjustment of loading positions. The articulation enables the load applicators to adapt their positions and orientations dynamically, ensuring uniform load distribution on test articles with varying heights and irregular shapes while maintaining system complexity at a manageable level
2Adaptability or versatility
If test loads are applied to CMC articles with varying heights, then the system is adaptable to different geometries, but peak stresses occur at contact points
Solution Approach 1:
The load application is segmented into multiple discrete loading points rather than a single concentrated load. By distributing the total load across multiple applicators contacting the test article at different locations, the system adapts to varying heights while reducing peak stress concentration at any single point
Solution Approach 2:
Each loading point is equipped with local articulation capabilities that allow independent adjustment to the local geometry of the test article surface. This local adaptability ensures optimal contact at each position, distributing loads evenly and preventing stress concentrations that would occur with fixed positioning
3Ease of operation
If a fixed loading position is used, then the system is simple to operate, but it cannot accommodate test articles with different heights
Solution Approach 1:
The loading system incorporates dynamic articulation mechanisms that automatically adjust to accommodate test articles of different heights and geometries. The articulation allows each load applicator to find its optimal position, providing geometric adaptability while maintaining ease of operation through automated adjustment rather than requiring manual reconfiguration
4Manufacturing precision
If multiple load applicators are used to distribute load, then load distribution is improved, but the device complexity increases
Solution Approach 1:
The loading system is divided into multiple independent but identical load applicator modules. Each module is a self-contained unit with its own articulation mechanism, allowing the system to achieve uniform load distribution through modular repetition rather than requiring a complex integrated design. This modularity manages device complexity by using standardized components
Solution Approach 2:
Multiple load applicators are equipped with articulation mechanisms that enable dynamic positioning. This dynamic capability allows the system to achieve precise load distribution on irregular geometries while maintaining operational simplicity through automated adjustment, balancing the trade-off between distribution precision and system complexity
Data Source
AI summary
The present disclosure relates to a material testing system for use in testing material strength of various gas turbine engine components. The material testing system provides a load force onto portions of gas turbine engine components.