CMC Turbine Vane Split Structure for Coreless Hollow Manufacturing
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Solution Overview
Problem
Manufacturing hollow turbine stator blades from ceramic matrix composite materials poses challenges due to the need for cores that can withstand high temperatures and maintain shape, while also requiring complex extraction processes.
Innovation Solution
The blade is constructed from two separate parts linked by a connecting interface, allowing coreless manufacturing and enabling features like local thickening, venting, and cooling solutions, with reinforcement through mechanical connections to maintain structural integrity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If a core is used during manufacturing to maintain the shape of hollow turbine stator blades, then the blade structure can be formed, but the manufacturing process becomes complex and difficult due to core extraction requirements
Solution Approach 1:
The invention removes the core from the manufacturing process entirely by using a closed-loop fibrous preform that maintains the hollow shape without requiring a removable core. The fibrous preform itself forms the hollow structure, eliminating the need for core extraction through melting, dissolution, or other complex processes.
Solution Approach 2:
The blade is divided into multiple sections along its length, with each section having its own closed-loop fibrous preform. These sections are then assembled together using linking interfaces, allowing the hollow structure to be formed from segmented components rather than requiring a single complex core.
2Temperature
If ceramic matrix composite materials are used for turbine stator blades, then high-temperature resistance and lightweight properties are achieved, but manufacturing difficulties increase due to core requirements
Solution Approach 1:
The invention extracts the core from the manufacturing process, allowing ceramic matrix composite blades to be manufactured without the complexity of core extraction. The closed-loop fibrous preform maintains the hollow shape inherently, simplifying the overall manufacturing process while preserving the high-temperature resistance benefits of CMC materials.
Solution Approach 2:
The hollow shape is prepared in advance through the closed-loop fibrous preform structure, which is formed before densification. This preliminary shaping action eliminates the need for subsequent core removal operations, simplifying the manufacturing process while maintaining the desired hollow geometry.
3Shape
If cores are used to maintain hollow blade shape during manufacturing, then the blade structure is formed, but additional manufacturing steps and difficulties are introduced
Solution Approach 1:
The invention removes the core and its associated manufacturing steps from the process. The closed-loop fibrous preform directly forms the hollow geometry without requiring core insertion, positioning, and extraction, thereby improving manufacturing efficiency and reducing process complexity.
Solution Approach 2:
The hollow geometry is prepared in advance through the closed-loop fibrous preform structure. This preliminary formation of the hollow shape eliminates the need for subsequent core removal operations, streamlining the manufacturing process and improving productivity.
Data Source
Figure 1~2A
Figure 2B~2C
Figure 3~4
AI summary
Turbine stator blade made of a ceramic matrix composite material comprising at least one hollow blade profile (100, 200, 300, 400, 500) having a trailing edge (BF) and a leading edge (BA), the blade comprising a first portion (110, 210, 310, 410, 510) comprising an extrados face of the blade profile and a second portion (120, 220, 320, 420, 520) distinct from the first portion and comprising an intrados face of the blade profile, the first and second portions being connected to one another by a connection interface (130, 230, 250, 260, 301, 302, 401) present at least on the trailing edge or leading edge of the blade profile, the connecting interface (401) comprising a region (402) of overlap between the first (410) and second (420) portions, which is present on at least one longitudinal end of the blade profile (400) and intended to be present outside a flow path (403) of a gas stream of the turbine, the blade also comprising at least one platform (530) present at one longitudinal end of the blade profile (500), the platform comprising a first portion (531) integral with the extrados face (510) of the blade profile and a second portion (520) integral with the intrados face (520) of the blade profile, the first and second portions of the platform being connected to one another on at least one straddling portion (533, 534) belonging to the region of overlap.