Ceramic Matrix Composite Turbine Vane Assembly
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Solution Overview
Problem
Design and manufacture of vanes and blades for gas turbine engines using composite materials face challenges due to the need for high-temperature resistance and structural strength, particularly in managing mechanical loads and maintaining aerodynamic efficiency.
Innovation Solution
A turbine vane assembly comprising composite aero vanes made of ceramic matrix composite materials and structural vanes, with a static seal element fixed to the structural vanes to manage mechanical loads, allowing the composite vanes to be free from these loads and focusing on aerodynamic performance, while the structural vanes handle pressure-induced stresses.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If composite materials are used for turbine vanes to withstand high temperatures, then temperature resistance is improved, but structural strength and load-bearing capacity deteriorate
Solution Approach 1:
The vane assembly is segmented into two distinct types: composite aero vanes (made of ceramic matrix composite materials) and structural vanes (made of metallic materials). This segmentation allows each type to perform its specialized function - composite vanes for high-temperature aerodynamic performance and structural vanes for mechanical load-bearing.
Solution Approach 2:
Different materials are applied to different locations based on functional requirements. Composite materials are used specifically where high-temperature resistance is critical (aero vanes), while metallic materials are used where structural strength is critical (structural vanes and seal support structures).
2Productivity
If composite aero vanes are used to improve aerodynamic efficiency, then aerodynamic performance is improved, but ability to carry mechanical loads deteriorates
Solution Approach 1:
The mechanical load-bearing function is extracted from the composite aero vanes and assigned to separate structural vanes. This allows the composite vanes to focus exclusively on aerodynamic functions without being compromised by mechanical load requirements.
Solution Approach 2:
Structural vanes act as intermediary elements that carry mechanical loads (including seal reaction forces) and transfer them to the engine case, thereby protecting the composite aero vanes from these loads while maintaining overall structural integrity.
3Reliability
If static seal element is attached to composite vanes, then sealing function is improved, but composite vanes are subjected to pressure-induced mechanical loads
Solution Approach 1:
Structural vanes serve as intermediary support structures that carry the static seal element and transfer seal reaction forces to the engine case. This intermediary arrangement protects the composite aero vanes from direct exposure to high seal loads.
Solution Approach 2:
The seal support structure is locally positioned on metallic structural vanes rather than on composite aero vanes, creating a localized load path that bypasses the composite materials and directs forces through metallic structures designed to handle them.
Data Source
AI summary
A turbine section adapted for use in a gas turbine engine includes a turbine case, a turbine wheel, and a turbine vane assembly. The turbine case is made from metallic materials. The turbine wheel is housed in the case. The turbine vane assembly is fixed to the case and configured to smooth and redirect air moving along a primary gas path of the turbine section.