Composite Abrasive Blade Tip for Heat-Resistant Sealing Rub

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Solution Overview

Problem

Abrasive tips in turbomachines face issues with heat conduction and delamination due to friction, especially when metal blades with overcoats and reinforcements rub against polymeric-based seals, leading to potential softening and loosening of adhesives, which compromises erosion protection and bond integrity.

Innovation Solution

The development of an abrasive tip comprising hard particles in a polymeric matrix with a high glass transition temperature and low thermal conductivity, along with optional fibers for reinforcement, is attached to the airfoil section using adhesives that are cured at lower temperatures to prevent softening and delamination.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If metal blades with overcoats and reinforcements are used to rub against polymeric seals, then erosion protection is improved, but heat conduction increases causing adhesive softening and delamination

Engineering Contradiction:

Improveerosion protectionVSAvoidheat conduction

Core Design Contradiction:

StrengthVSTemperature

Solution Approach 1:

The blade tip is constructed as a composite structure with a metal substrate providing erosion protection, and a polymeric matrix composite tip material with low thermal conductivity attached to it. This composite design allows the metal substrate to provide mechanical strength and erosion resistance while the polymeric composite tip material reduces heat conduction to the adhesive, preventing softening and delamination.

Inventive Principle:

Principle #40Composite materials

2Temperature

If high glass transition temperature polymeric matrix material is used for abrasive tip, then heat resistance is improved, but manufacturing complexity increases

Engineering Contradiction:

Improveheat resistanceVSAvoidmanufacturing complexity

Core Design Contradiction:

TemperatureVSEase of manufacture

Solution Approach 1:

The polymeric matrix material is prepared in a prepeg form with fibers already impregnated with the matrix material before attachment to the blade tip. This preliminary preparation simplifies the manufacturing process by eliminating the need for complex in-situ matrix application and consolidation steps during blade assembly, while still achieving the desired high glass transition temperature and structural integrity.

Inventive Principle:

Principle #10Preliminary action

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 solution provides improved heat resistance and maintains the abrasive tip's structural integrity, reducing heat transfer and adhesive softening, thereby enhancing the longevity and performance of the abrasive tip.

Implementation Method 1

The matrix material has a glass transition temperature greater than or equal to 225 degrees C. (437 degrees F.).

Methodology Applied

Scientific EffectGlass transition temperature:

Implementation Method 2

abrasive tip comprising hard particles in a polymeric matrix with a high glass transition temperature and low thermal conductivity

Methodology Applied

Scientific EffectThermal conductivity: Conduction (thermal)

Data Source

PatentUS20260049554A1Blade with abrasive tip

Publication Date: 2026.02.19 RTX CORP

AI summary

A method of fabricating a blade includes fabricating an abrasive tip and then attaching the abrasive tip to a free end of an airfoil section of a blade. The abrasive tip comprises particles disposed in a matrix material.