CMC Turbine Component Inserts With Tapered Ends for Shape Integrity
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Solution Overview
Problem
Forming complex shapes in gas turbine engine components using ceramic matrix composite (CMC) plies is challenging, particularly in maintaining component integrity under high-temperature conditions.
Innovation Solution
The use of CMC fabric layers with inserts having tapered ends, formed through a compression process using molds with curved portions to create thinner ends, and the incorporation of noodles made of different materials to facilitate bending, along with the use of a binder for stabilization during the formation process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If CMC plies are used to form turbine section components, then high-temperature resistance is improved, but manufacturing complexity increases
Solution Approach 1:
The component is constructed from multiple discrete CMC plies that are stacked and formed into the final shape. This segmentation allows each ply to be manufactured and prepared separately, then assembled into the complex three-dimensional turbine component structure, making the manufacturing process more manageable despite the inherent complexity of working with CMC materials.
Solution Approach 2:
The patent utilizes ceramic matrix composite (CMC) materials, which are composite materials consisting of ceramic fibers embedded in a ceramic matrix. This composite structure provides superior high-temperature resistance compared to traditional metals, enabling the turbine components to operate in the extreme thermal environment of the turbine section while maintaining structural integrity.
2Adaptability or versatility
If complex shapes are formed using CMC plies, then component functionality is improved, but manufacturing precision deteriorates
Solution Approach 1:
The manufacturing process transitions from two-dimensional ply stacking to three-dimensional complex shapes by forming the plies into curved and angled configurations. The plies are arranged in specific orientations and stacked in sequences that build up the complex three-dimensional geometry of turbine components such as blades and vanes, enabling functionality required for aerodynamic performance while managing the challenges of precision formation.
3Strength
If inserts with tapered ends are used, then structural integrity is improved, but manufacturing complexity increases
Solution Approach 1:
The inserts incorporate tapered ends at specific locations where structural reinforcement is needed, rather than uniformly throughout the entire insert. This local quality approach provides enhanced structural integrity at critical stress points while keeping the rest of the insert design simpler, balancing the need for strength with manufacturing complexity.
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 method allows for the creation of robust, high-temperature-resistant components with reduced thickness variations, enhancing the structural integrity and performance of gas turbine engine parts.
Implementation Method 1
bringing a second mold half onto the plurality of fabric layers to compress the fabric layers at an end associated with the at least one curved portion of the first mold half to form an insert having a thinner thickness at the at least one end than found at an intermediate portion spaced from the at least one end
Data Source
AI summary
A component includes fabric layers of ceramic matrix composite (“CMC”) fabric. The fabric has layers separated by an insert formed of the CMC fabric. The insert has at least one tapered end. The tapered end has a thickness which is less than a central thickness of the insert. A method is also disclosed.