Ceramic Matrix Composite Tip Region Formation via Preform Rigidization
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing methods for forming ceramic matrix composite (CMC) components for gas turbines are labor-intensive and prone to part fallout and ply squeezing during assembly, leading to fragile components and increased costs.
Innovation Solution
A process involving positioning core plies on a mandrel, partially rigidizing them to form a preform CMC arrangement with a tip cavity, and then applying and densifying ceramic matrix composite tip plies to create a robust tip region, reducing the need for additional hand lay-up steps and minimizing component fragility.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a CMC laminate tip cap is formed by cutting out and laying up multiple plies to fill the open tip area, then the tip area can be closed, but the process becomes time and labor intensive and the components remain fragile
Solution Approach 1:
The tip cap plies are pre-formed and pre-shaped before assembly, allowing the fragile CMC components to be prepared in advance without requiring complex assembly operations. The plies are shaped to match the tip cavity geometry beforehand, eliminating the need for time-consuming on-site cutting and laying up operations.
Solution Approach 2:
The tip cap is divided into multiple plies that are individually shaped and then assembled together. This segmentation allows each ply to be optimized independently and assembled into the final tip cap structure, reducing the complexity of handling and assembling the complete tip cap as a single fragile piece.
2Reliability
If multiple CMC plies are hand laid up and assembled into the tip area, then the tip cavity can be filled, but the components are easily damaged during assembly due to their fragile state
Solution Approach 1:
The tip cap plies are pre-shaped and pre-prepared before assembly operations. This preliminary shaping allows the plies to be ready for direct insertion into the tip cavity without requiring complex assembly operations, reducing the risk of damage during handling and assembly.
Solution Approach 2:
A mandrel is used as an intermediary tool to shape and position the tip cap plies during assembly. The mandrel provides structural support and guidance, allowing the fragile plies to be positioned accurately without direct manual handling that could cause damage.
3Manufacturing precision
If the CMC preform is processed through traditional hand lay-up methods, then the component can be formed, but significant ply squeezing occurs during fabrication
Solution Approach 1:
The tip cap plies are pre-shaped and pre-positioned before final assembly. This preliminary preparation ensures proper ply positioning and eliminates the need for forceful squeezing during assembly, as the plies are already configured in their final positions.
Solution Approach 2:
The mandrel serves as an intermediary that maintains proper spacing and positioning of the plies during assembly. By using the mandrel to hold and position the plies, the process eliminates direct compression and squeezing that would occur with traditional hand lay-up methods.
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
This approach results in a more cost-effective and robust CMC airfoil system with reduced part fallout and ply squeezing, enabling the production of durable CMC components for gas turbines with enhanced structural integrity.
Implementation Method 1
partially rigidizing the core plies to form a preform ceramic matrix composite arrangement
Implementation Method 2
The ceramic matrix composite tip plies are densified to form a tip region of the composite component
Data Source
Figure 1
Figure 2
Figure 3~8
AI summary
A process of producing a ceramic matrix composite component 10. The process includes positioning core plies 62 on a mandrel. At least partially rigidizing the core plies 62 to form a preform ceramic matrix composite arrangement defining a tip cavity 301 and a hollow region. Ceramic matrix composite tip plies 303 are positioned on the preform ceramic matrix composite arrangement and within the tip cavity 301. The ceramic matrix composite tip plies 303 are densified to form a tip region 30 of the composite component 10.