CMC Vane Preform Layup for Uniform Fiber Architecture
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Solution Overview
Problem
Conventional layup techniques for ceramic matrix composite components in gas turbine engines result in distortions and reduced fiber regions, leading to non-uniform density and performance issues.
Innovation Solution
A method involving the use of bi- or triaxial braided ceramic fabrics for cores and contoured plies, along with a tackifier composition, to form a ceramic preform that minimizes fiber distortions and ensures continuous fiber architecture throughout the vane, followed by densification with a matrix.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional layup techniques are used for ceramic matrix composite components, then the manufacturing process is simple, but fiber distortions and reduced fiber regions occur leading to non-uniform density
Solution Approach 1:
The preform is divided into multiple contoured plies, each made from unidirectional preimpregnated ceramic tapes. Each ply is laid up separately with precise fiber orientation control, allowing the complex 3D architecture to be built incrementally without distortions that would occur in conventional single-step layup techniques.
Solution Approach 2:
The patent transitions from conventional 2D layup techniques to a 3D contoured ply architecture. Each ply is contoured to match the complex curvature of the final component geometry, allowing fibers to follow the desired path in three dimensions while maintaining uniform distribution and eliminating the fiber distortions inherent in flat layup methods.
2Shape
If complex curvatures and features are included in turbine engine components, then the component design is optimized for performance, but conventional layup techniques result in distortions and reduced fiber regions
Solution Approach 1:
The patent employs contoured plies that are pre-formed with the desired curved geometry matching the target component shape. Each ply is contoured to follow the complex surfaces and features of the final part, allowing the fiber architecture to naturally conform to the curvature without the distortions that occur when forcing flat materials into curved shapes using conventional techniques.
Solution Approach 2:
The invention changes the fundamental parameters of the layup process by using unidirectional preimpregnated ceramic tapes instead of conventional woven fabrics. This allows independent control of fiber orientation, spacing, and contouring for each ply, enabling precise fabrication of complex curved geometries while maintaining uniform fiber distribution throughout the preform.
3Reliability
If uniform density is achieved in the final component, then performance and durability are improved, but the layup process becomes more complex requiring precise fiber architecture control
Solution Approach 1:
The patent performs preliminary action by pre-forming each ply with the exact contour and fiber orientation required for the final component geometry. The unidirectional preimpregnated ceramic tapes are prepared in advance with controlled fiber spacing and orientation, so that when laid up in sequence, they automatically create the uniform fiber architecture needed for consistent density and reliable performance without requiring complex post-processing or adjustment.
Data Source
AI summary
A method of forming a ceramic matrix composite (CMC) vane including an inner diameter platform, an outer diameter platform, and an airfoil extending between the inner diameter platform and the outer diameter platform includes laying up a ceramic preform by arranging at least one core formed from a first ceramic material, and laying up, over the at least one ceramic core, a plurality of contoured plies, each of the plurality of contoured plies formed from a second ceramic material. Each of the plurality of contoured plies partially forms the inner diameter platform, the outer diameter platform, and the airfoil of the vane. The method further includes densifying the ceramic preform with a matrix.