Ceramic Matrix Composite Vane Assembly with Metallic Spar
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Solution Overview
Problem
Gas turbine engine vanes face challenges in withstanding high temperatures while maintaining a lightweight structure, as thicker metallic vanes increase weight, and ceramic matrix composite vanes are prone to structural failures under load.
Innovation Solution
A vane assembly with an airfoil design featuring a metallic support spar and a ceramic matrix composite airfoil body, where the airfoil body has varying chord lengths and a constant leading edge radius, optimized to direct gases efficiently and structurally support the vane, incorporating a metallic spar and ceramic matrix composite materials.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If thicker metallic vanes are used to withstand high temperatures, then temperature resistance is improved, but weight increases
Solution Approach 1:
The patent applies composite materials by combining ceramic matrix composite (CMC) airfoil body with a metallic support spar. The CMC material provides high-temperature resistance while being lighter than solid metal, and the metallic spar reinforces structural strength. This composite structure resolves the contradiction by achieving temperature resistance without the weight penalty of thicker metallic vanes.
Solution Approach 2:
The patent applies local quality by using different materials in different regions of the vane. The airfoil body is made of CMC for high-temperature exposure areas, while the internal spar uses metallic material for structural support. This localized material selection optimizes both weight and temperature resistance by placing each material where it is most effective.
2Weight of moving object
If ceramic matrix composite materials are used to decrease weight, then weight is reduced, but structural strength deteriorates under load
Solution Approach 1:
The patent uses composite materials to resolve the strength-deterioration issue of CMC. By integrating a metallic support spar within the CMC airfoil body, the composite structure combines the lightweight advantage of CMC with the high strength of metal. The metallic spar carries structural loads while the CMC provides thermal resistance and overall form, achieving both weight reduction and maintained strength.
Solution Approach 2:
The patent applies segmentation by dividing the vane into functional segments: the CMC airfoil body for aerodynamic and thermal functions, and the metallic spar for structural support. This segmentation allows each material to perform its optimal function, with the metallic spar specifically addressing the strength limitation of CMC under load.
3Productivity
If varying chord lengths are used to optimize aerodynamic shape, then aerodynamic efficiency is improved, but manufacturing complexity increases
Solution Approach 1:
The varying chord length design applies local quality by optimizing the airfoil geometry at different spanwise locations. The chord length changes from root to tip to match the local flow conditions and structural requirements. This localized geometric optimization improves aerodynamic efficiency while the modular CMC construction methods help manage manufacturing complexity.
Data Source
AI summary
A turbine assembly for use with a gas turbine engine includes a bladed wheel assembly and a vane assembly. The bladed wheel assembly is adapted to interact with gases flowing through a gas path of the gas turbine engine. The vane assembly is located upstream of the bladed wheel assembly and adapted to direct the gases at the bladed wheel assembly.