Gas Turbine Combustor Liner with Embedded 3D Ceramic Fiber Fabric
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Solution Overview
Problem
Gas turbine combustor liners face challenges in withstanding high temperature cycles, as traditional materials like superalloys are expensive, and ceramic matrix composites are prone to fiber damage, delamination, and oxidation, leading to material discontinuities and embrittlement.
Innovation Solution
A combustor liner comprising a monolithic ceramic block with a 3D fabric of ceramic fibers partially embedded and extending outside, which bridges cracks and holds the block together, reducing exposure to high temperatures and eliminating the need for protective coatings, using oxide ceramic materials like alumina or zirconium dioxide.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If traditional superalloys are used for combustor liners, then temperature resistance is improved, but cost increases significantly
Solution Approach 1:
The patent uses a composite structure combining monolithic ceramic block with 3D fabric of ceramic fibers. The ceramic material provides high temperature resistance comparable to superalloys, while the composite architecture reduces cost by eliminating the need for expensive nickel-based superalloys and their associated manufacturing processes
Solution Approach 2:
The invention applies different ceramic material properties to different regions: the monolithic ceramic block faces the combustion chamber for maximum temperature resistance, while the 3D ceramic fiber fabric provides structural support and crack bridging in regions experiencing thermal stress, optimizing both performance and cost-effectiveness
2Ease of manufacture
If ceramic matrix composites are used for combustor liners, then cost is reduced, but reliability deteriorates due to fiber damage, delamination, and oxidation
Solution Approach 1:
The patent incorporates a 3D fabric of ceramic fibers within the monolithic ceramic block before operation. This pre-integrated fiber network acts as a safety mechanism that bridges cracks and prevents catastrophic failure, compensating for the inherent brittleness of ceramic materials before damage occurs
Solution Approach 2:
The 3D ceramic fiber fabric serves as an intermediary element between the monolithic ceramic block and the external environment. It mediates stress distribution, prevents crack propagation, and protects the ceramic structure from oxidation and thermal shock, thereby enhancing overall reliability
3Object-affected harmful factors
If protective coatings are applied to ceramic liners, then oxidation resistance is improved, but device complexity increases
Solution Approach 1:
The patent uses oxide ceramic materials (alumina, zirconium dioxide, silicon oxide) that inherently possess high oxidation resistance. The material itself provides the protective function without requiring additional protective coatings, thereby eliminating the complexity of multi-layer coating systems while maintaining oxidation protection
4Ease of manufacture
If monolithic ceramic blocks are used without fiber reinforcement, then manufacturing is simplified, but strength deteriorates under thermal stress
Solution Approach 1:
The patent creates a composite ceramic structure by integrating 3D fabric of ceramic fibers within the monolithic ceramic block. This composite architecture maintains manufacturing simplicity while dramatically improving strength and crack resistance under thermal stress conditions
Solution Approach 2:
The ceramic fibers are embedded within the monolithic block during manufacturing, creating a pre-reinforced structure before the component is subjected to service conditions. This preliminary reinforcement ensures the structure can withstand thermal stresses from the outset without requiring post-manufacturing modifications
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
This configuration enhances durability and temperature resistance, allowing for the use of cheaper, environmentally friendly materials, improving engine performance and reducing emissions by maintaining liner integrity and avoiding cooling air wastage.
Implementation Method 1
a 3D fabric of ceramic fibers partially embedded inside the monolithic ceramic block, and partially extending outside the second face of the monolithic ceramic block... the ceramic fibers extending outside the second face bridge the two fractions of the monolithic ceramic block to one another and hold them together
Implementation Method 2
a cooling flow path extending alongside the second face
Data Source
Figure 1
Figure 2
Figure 3~5
AI summary
A gas turbine combustor liner (20) delimits a combustion chamber (24) and has at least one monolithic ceramic block (30) having a first face (42) exposed to the combustion chamber (24) and a second face opposite the first face (42), and a 3D fabric of ceramic fibers (28) partially embedded inside the monolithic ceramic block (30), and partially extending outside the second face of the monolithic ceramic block (30), away from the combustion chamber (24).