Ceramic Matrix Composite Turbine Vane Manufacturing via Nested Preforms
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Solution Overview
Problem
Existing methods for manufacturing turbine distributor blades made of ceramic matrix composite (CMC) materials face challenges in achieving simple and efficient production while ensuring resistance to operational forces and maintaining desired aerodynamic and cooling functions.
Innovation Solution
A method involving separate fibrous preforms, including a hollow central part and lateral parts, are assembled with second preforms having debonding zones to form platforms, followed by the formation of a common ceramic matrix, simplifying manufacturing and enhancing structural resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a single integrated preform is used to manufacture the blade, then the structural strength and resistance to operational forces are improved, but the manufacturing complexity and difficulty increase significantly
Solution Approach 1:
The blade structure is divided into separate functional preforms: a first preform for the blade body and aerodynamic functions, and a second preform for the platforms and cooling functions. This segmentation allows each component to be manufactured and assembled separately, reducing overall manufacturing complexity while maintaining structural integrity through controlled bonding interfaces.
Solution Approach 2:
The second preform is inserted into the first preform in a nested configuration, with the platform preform positioned within the blade body preform. This nesting approach enables precise positioning and integration of multiple functional elements while simplifying the assembly process compared to creating a single complex integrated preform.
2Ease of manufacture
If the blade structure is simplified for easier manufacturing, then the manufacturing process becomes simpler and more efficient, but the ability to route forces through structurally strong zones is compromised
Solution Approach 1:
Different regions of the blade are assigned different functional qualities: the blade body preform provides aerodynamic shaping and primary structural strength, while the platform preform provides cooling air routing and platform functions. Each preform is optimized for its specific function, allowing the overall structure to achieve both manufacturing simplicity and force routing capability through functional specialization.
Solution Approach 2:
The blade is constructed as a composite structure using two distinct fiber preforms that are bonded together. This composite approach allows each preform to contribute its specific mechanical properties and functional characteristics, achieving superior overall performance that combines the strengths of both components while maintaining manufacturing efficiency.
3Productivity
If multiple separate preforms are assembled to form the blade, then the manufacturing process is simplified and productivity increases, but the structural integrity and resistance to forces may be reduced
Solution Approach 1:
The fiber preforms are prepared and pre-shaped before assembly, with all necessary structural features and functional elements already in place. This preliminary preparation allows for efficient assembly without compromising structural integrity, as each preform arrives ready-to-install with its specific function optimized beforehand.
Solution Approach 2:
A bonding interface or intermediary material is used to join the first and second preforms together. This bonding mechanism ensures strong structural connection between the separate preforms, maintaining structural integrity and force routing capability while still allowing for the manufacturing efficiency gains of using separate components.
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 simplifies the manufacturing process and enhances the structural integrity and aerodynamic performance of CMC turbine distributor blades, ensuring effective force distribution and gas flow management.
Implementation Method 1
the assembly of one of the second fiber preforms with the first fiber preform by inserting the central part into the opening of the second fiber preform considered and by positioning the inner lateral part between the skins of the second fiber preform considered
Implementation Method 2
each second fiber preform having two skins bonded on a second edge of the second fiber preform considered, distinct from the first edge
Implementation Method 3
the joining of the second preforms thus assembled with the first preform by forming a common ceramic matrix between these preforms
Data Source
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AI summary
The present invention relates to a method for manufacturing a turbine nozzle guide vane from a ceramic matrix composite material.