CMC Vane Arc Segment Flange Step for Load Transmission
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Solution Overview
Problem
Implementing ceramic matrix composite (CMC) materials in gas turbine engine airfoils is challenging due to unique manufacturing and integration issues, particularly in forming and coating complex geometries like vane arc segments.
Innovation Solution
A vane arc segment design featuring airfoil fairings made of CMC with specifically structured flanges and radial step faces that are non-coated and flush with a wear-resistant coating, allowing for efficient load transmission and sealing, along with a method of fabricating these segments by depositing a coating on the non-gaspath side and removing sections to form steps that act as bearing faces.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Duration of action of stationary object
If CMC materials are used for airfoils to extend temperature capability and lifetime, then temperature resistance and durability are improved, but manufacturing complexity and integration challenges increase
Solution Approach 1:
The airfoil is divided into modular segments (vane arc segments) that can be manufactured separately and assembled. Each segment includes an airfoil fairing, flange, and platform as distinct but integrated components, allowing independent manufacturing and quality control of CMC components while simplifying overall production
Solution Approach 2:
Different regions of the airfoil structure have different material properties and coating applications. The CMC material is applied specifically to the airfoil fairing where high temperature resistance is needed, while other areas may use different materials or no coating, optimizing both performance and manufacturability
2Strength
If a coating is applied to the flange for wear resistance, then wear resistance is improved, but sealing capability and load transmission are compromised
Solution Approach 1:
The coating is applied selectively to specific surfaces of the flange (radial outer surface and circumferential surfaces) while leaving other surfaces uncoated. This allows wear resistance where needed while maintaining sealing capability and load transmission at contact surfaces
Solution Approach 2:
The flange surface is divided into coated and uncoated zones, with the coating applied only to non-contact surfaces. The uncoated surfaces maintain their native properties for sealing and load bearing, while coated surfaces gain wear resistance
3Strength
If the flange geometry is designed for optimal load transmission, then structural performance is improved, but manufacturing and coating integration become more difficult
Solution Approach 1:
The flange is designed as a separate manufacturable component that can be produced independently of the airfoil fairing. This segmentation allows each component to be optimized for its specific manufacturing process while maintaining the overall load transmission functionality
Solution Approach 2:
The flange serves multiple functions: structural load transmission, sealing surface provision, and coating substrate. By integrating these functions into a single component with carefully designed geometry, the design achieves optimal load transmission while remaining manufacturable
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
The solution enables effective integration of CMCs in gas turbine engines by enhancing load transmission and sealing capabilities, improving the durability and performance of vane arc segments while simplifying the manufacturing process.
Implementation Method 1
A coating is deposited along at least a portion of the non-gaspath side adjacent the end portion of the flange
Data Source
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AI summary
A vane arc segment (60) includes an airfoil fairing (62) that has a platform (66, 68) and an airfoil section (64) that extends therefrom. The platform (66, 68) defines periphery edge faces (72), a gaspath face (74a), and a non-gaspath face (74b). The platform (66, 68) has a flange (76) that projects radially from the non-gaspath face (74b). The flange (76) defines a forward flange face (76a), an aft flange face (76b), and a radial flange face (76c). The flange (76) has an end portion (78) adjacent one of the periphery edge faces (72). The end portion (78) includes a step (80) that defines a radial step face (80a) that is radially intermediate the radial flange face (76c) and the non-gaspath face (74b).