Ceramic Matrix Composite Life Extension via Dynamic Thermal Scheduling

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Solution Overview

Problem

Ceramic matrix composite components in gas turbine engines face degradation due to thermal cycling and other operational stresses, leading to integrity issues and reduced lifespan.

Innovation Solution

A gas turbine engine system with a controller that utilizes a degradation mechanism map to manage stress and temperature, allowing the engine components to be moved between different degradation fields to minimize damage, thereby extending the lifespan of ceramic matrix composite materials.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Temperature

If ceramic matrix composite components are used in gas turbine engines to withstand high temperatures, then temperature resistance is improved, but degradation from thermal cycling and operational stresses reduces component lifespan

Engineering Contradiction:

Improvetemperature resistanceVSAvoidcomponent lifespan

Core Design Contradiction:

TemperatureVSReliability

Solution Approach 1:

The patent applies dynamics by transitioning from static operating conditions to dynamic operation schedules that actively vary temperature and stress parameters over time. The controller dynamically adjusts operational parameters to move components through different degradation fields, optimizing component life while maintaining performance. This is achieved through time-varying operation schedules that modulate thermal and mechanical loads.

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

The patent implements parameter changes by modifying temperature and stress parameters according to predefined operation schedules. The controller changes operational parameters (temperature, stress, duration of exposure) to navigate through degradation fields, avoiding prolonged exposure to detrimental conditions. This involves systematically varying operational parameters to achieve optimal component life.

Inventive Principle:

Principle #35Parameter changes

2Power

If high temperatures are maintained for optimal engine performance, then power output is improved, but degradation mechanisms accelerate and reduce component integrity

Engineering Contradiction:

Improvepower outputVSAvoiddegradation from thermal cycling

Core Design Contradiction:

PowerVSObject-affected harmful factors

Solution Approach 1:

The patent applies periodic action through operation schedules that implement cyclic variations in temperature and stress exposure. Instead of continuous high-temperature operation, the system uses periodic cycles that alternate between high-performance modes and reduced-load modes, allowing components to recover and avoiding cumulative degradation from sustained thermal cycling.

Inventive Principle:

Principle #19Periodic action

Solution Approach 2:

The patent implements skipping by rapidly transitioning through detrimental degradation fields rather than dwelling in them. The operation schedules are designed to quickly pass through temperature-stress combinations that cause severe degradation, minimizing exposure time to harmful conditions while maintaining overall engine performance.

Inventive Principle:

Principle #21Skipping (Rushing through)

3Duration of action of stationary object

If operation schedules are optimized to extend component life, then component lifespan is improved, but engine productivity may be reduced due to altered operating patterns

Engineering Contradiction:

Improvecomponent lifespanVSAvoidengine output

Core Design Contradiction:

Duration of action of stationary objectVSProductivity

Solution Approach 1:

The patent applies partial action by implementing operation schedules that use high-performance operating modes selectively rather than continuously. The optimized schedules apply full power output only when necessary, while using reduced-load modes during other periods to minimize degradation. This partial utilization of maximum capacity extends component life while maintaining adequate overall productivity.

Inventive Principle:

Principle #16Partial or excessive action

Data Source

PatentUS11536205B2Gas turbine engine operating schedules for optimizing ceramic matrix composite component life

Publication Date: 2022.12.27 ROLLS ROYCE PLC

AI summary

A gas turbine engine system includes an engine component comprising ceramic matrix composite materials, at least one control system configured to control at least a temperature of the engine component, and a controller. The controller includes a degradation map stored therein. The degradation map includes degradation fields, each field defined by a unique range of temperatures and stresses of the component and correlated to different types of degradation of the component. The controller is configured to determine a first temperature and stress of the component and a first field based on the first temperature and stress, determine a second field different from the first and a second temperature and stress that would locate the component in the second field, and instruct the control system to change the temperature of the component from the first to the second temperature to locate the component in the second field.