CMC Vane Overwrap Reinforcement for Delamination Prevention
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Solution Overview
Problem
Ceramic Matrix Composite (CMC) components in gas turbine engines face challenges in maintaining structural integrity and preventing delamination in high-temperature, oxidizing environments, particularly due to the complexity of fiber orientation and stress distribution in vane structures.
Innovation Solution
A vane structure for gas turbine engines featuring T-shaped platform segments with preformed monolithic ceramic fillers and an overwrap of CMC material, where the fillers are triangular in cross-section and the overwrap is wound in a spiral manner to reinforce the T-sections, reducing the risk of delamination and enhancing hoop strength.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If CMC materials are used in vane structures, then temperature capability and strength to weight ratio are improved, but manufacturing complexity increases due to fiber orientation requirements
Solution Approach 1:
The vane structure is divided into multiple plies with different fiber orientations (0 degrees, 45 degrees, 90 degrees) that can be manufactured separately and then assembled. This segmentation allows each ply to be optimized for specific stress directions while simplifying the overall manufacturing process compared to creating a single complex monolithic structure with varying fiber orientations.
Solution Approach 2:
The invention uses composite materials consisting of CMC plies combined with metal alloy materials in the T-shaped platform segments. This composite approach allows the CMC to provide high-temperature capability while the metal alloy provides ductility and ease of manufacturing, thereby reducing overall manufacturing complexity while maintaining temperature resistance.
2Strength
If T-shaped platform segments are used in vane structures, then structural integrity is improved, but delamination risk increases in high-temperature environments
Solution Approach 1:
The T-shaped platform segments are pre-formed with integrated reinforcement features before assembly into the final vane structure. This preliminary action allows for pre-positioning of reinforcement elements that will prevent delamination during subsequent high-temperature operation, rather than attempting to address delamination issues after the structure is assembled and subjected to thermal stress.
Solution Approach 2:
The T-shaped platform segments incorporate localized reinforcement features at critical interfaces where delamination is most likely to occur. This local quality approach applies enhanced material properties or structural features only where needed, rather than uniformly throughout the entire structure, thereby improving delamination resistance while maintaining overall structural integrity.
3Stability of the object's composition
If fiber-reinforced prepreg tapes are used to connect vane units, then structural continuity is improved, but manufacturing precision requirements increase
Solution Approach 1:
The continuous fiber-reinforced structure is segmented into discrete prepreg tapes that can be manufactured to standard dimensions and then assembled. This segmentation transforms the challenge of manufacturing one long continuous structure with high precision into manufacturing multiple smaller, standardized components that are easier to align and assemble with less stringent precision requirements.
Solution Approach 2:
The T-shaped platform segments serve multiple functions: they provide structural support, act as connection points for prepreg tapes, and incorporate reinforcement features. This multi-functionality reduces the number of separate components needed, thereby reducing the cumulative alignment precision requirements that would arise from assembling many individual parts.
Data Source
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AI summary
A vane structure (66) for a gas turbine engine includes an airfoil section (68) with a platform segment (78,80) adjacent to a ring (106,108). An insert (110) is adjacent to the platform segment (78,80) and an overwrap (112) is wound around the ring (106,108) and the insert (110).