Profiled Endwall Tooling for CMC Vane Secondary Loss Reduction
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Solution Overview
Problem
Manufacturing profiled endwalls in ceramic matrix composite (CMC) components for gas turbine engines poses design challenges, particularly in reducing secondary losses due to flow overturning and pressure gradients, which existing methods have not adequately addressed.
Innovation Solution
A method involving multi-piece tooling with core and profiled endwall tools is used to form three-dimensional contoured surfaces on CMC components, allowing for the creation of profiled endwalls with complex geometries that reduce flow overturning and secondary losses by modifying the local static pressure field.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If profiled endwalls are manufactured in CMC components using conventional methods, then the manufacturing process is simple, but the ability to reduce secondary losses and improve aerodynamic efficiency is insufficient
Solution Approach 1:
The tooling system is divided into multiple segments: a core tool for the main body, an endwall tool for the endwall region, and a shroud tool for the shroud region. These segmented tools can be assembled together to form a complete molding cavity, allowing complex profiled geometries to be created while maintaining manufacturing feasibility through modular tooling approaches
Solution Approach 2:
The invention transitions from conventional two-dimensional or simple three-dimensional molding to complex multi-dimensional profiling by incorporating specialized endwall and shroud tools that create intricate surface geometries in multiple directions, enabling the formation of profiled endwalls with curved surfaces that optimize aerodynamic flow patterns
2Manufacturing precision
If complex profiled geometries are created in CMC components, then aerodynamic efficiency is improved, but the manufacturing process becomes more difficult
Solution Approach 1:
The core tool, endwall tool, and shroud tool are pre-assembled into a complete molding cavity structure before the CMC manufacturing process begins. This preliminary assembly ensures that the complex profiled geometries are already configured in the tooling, allowing the CMC material to be formed into the precise desired shape during infiltration without requiring complex in-situ adjustments
Solution Approach 2:
The segmented tooling system acts as an intermediary between the manufacturing process and the final complex geometry. The tools transmit and shape the CMC material into the desired profiled endwall configuration, mediating the transformation from simple preform to complex aerodynamic shape while maintaining manufacturing control
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 method enables the efficient manufacture of profiled endwalls in CMC components, leading to a significant reduction in engine fuel burn by minimizing secondary losses and improving aerodynamic efficiency.
Implementation Method 1
the porous preform is placed in a mold and an infiltrant material is infiltrated into the porous preform under vacuum and heat
Implementation Method 2
the porous preform is placed in a mold and an infiltrant material is infiltrated into the porous preform under vacuum and heat
Data Source
Figure 1
Figure 2~3
Figure 4A~4B
AI summary
Systems and methods of forming a ceramic matrix composite vane with profiled endwalls are provided using a multi-piece tooling. The multi-piece tooling includes core tools as well as profiled endwall tools having three dimensional contours formed in the tools that correspond to the three dimensional shape to be formed on the vane endwalls.