CMC Turbine Nozzle Shell Assembly via Interleaved Platform Fingers
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Solution Overview
Problem
Conventional gas turbine nozzles face inefficiencies due to high cooling air requirements and stress issues at joints, particularly in ceramic matrix composite (CMC) components with complex geometries, leading to reduced durability and longer production times.
Innovation Solution
A method for manufacturing CMC turbine nozzle shells involves assembling and joining preforms with stacked and hot-debulked platform plies, composite wrap plies with unidirectional fibers, and a core preform, which are then interleaved and rigidized to reinforce joints and reduce production time.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional assembly methods are used for CMC turbine nozzles, then manufacturing precision can be maintained, but production time increases significantly
Solution Approach 1:
The turbine nozzle is divided into separate preformed sections (airfoil body, inner platform, outer platform) that are manufactured independently and then assembled. This segmentation allows parallel manufacturing of components, reducing overall production time while maintaining precision through specialized tooling for each section.
Solution Approach 2:
The preforms are prepared in advance with predetermined geometries and fiber orientations before final assembly. This preliminary shaping and positioning of components enables faster final assembly while ensuring manufacturing precision is achieved through pre-planned component configurations.
2Loss of energy
If CMC materials are used to reduce cooling air requirements, then gas turbine efficiency improves, but stress concentration occurs at joints between airfoil body and platforms
Solution Approach 1:
The turbine nozzle utilizes ceramic matrix composite materials that provide superior thermal resistance and mechanical properties. The composite structure allows the nozzle to withstand high temperatures with reduced cooling air requirements while maintaining structural integrity at joint regions through the inherent properties of CMC materials.
Solution Approach 2:
The fiber orientation and material properties are optimized locally at joint regions between the airfoil body and platforms. The preforms are designed with specific fiber orientations that concentrate reinforcement at stress-prone areas, providing enhanced local strength where needed while maintaining overall component performance.
3Adaptability or versatility
If complex geometry is incorporated into turbine nozzles, then functional performance improves, but assembly time and complexity increase
Solution Approach 1:
The complex geometry of the turbine nozzle is divided into separate preformed sections, each with simplified individual geometries that are easier to manufacture. The segmentation allows complex overall shapes to be achieved through assembly of simpler components, reducing assembly complexity while maintaining functional performance.
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 enhances the durability and efficiency of CMC nozzle production by reducing stress at joints and shortening manufacturing time, improving the thermal capabilities and longevity of gas turbine components.
Implementation Method 1
assembling a primary outer nozzle platform, a primary inner nozzle platform, a core and trailing edge preform, and an airfoil-shaped body; joining the primary outer nozzle platform to a secondary outer nozzle platform of the airfoil-shaped body
Data Source
AI summary
A method of manufacturing a ceramic matrix composite (CMC) turbine nozzle shell is provided. The method includes: assembling a primary outer nozzle platform, a primary inner nozzle platform, a core and trailing edge preform, and an airfoil-shaped body; joining the primary outer nozzle platform to a secondary outer nozzle platform of the airfoil-shaped body; and joining the primary inner nozzle platform to a secondary inner nozzle platform of the airfoil-shaped body. Composite plies circumferentially surround the airfoil-shaped body, and their longitudinal edges are cut into fingers that are folded down. The fingers are interleaved between secondary platform plies to form the secondary outer and inner nozzle platforms.