Composite Turbine Airfoil Assembly for High-Temperature Strength

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Solution Overview

Problem

Turbine engine components, particularly those in high-temperature sections, require materials that offer a high strength-to-weight ratio and can withstand extreme temperatures, while existing materials like superalloys are heavy and have limitations in thermal durability.

Innovation Solution

The use of composite airfoil assemblies made from fiber-reinforced matrix materials, including polymer matrix composites (PMCs) and ceramic matrix composites (CMCs), which are designed with inner support structures and laminate overlays to enhance structural integrity and thermal resistance.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If superalloys are used for turbine engine components, then strength and thermal durability are improved, but weight increases

Engineering Contradiction:

ImprovestrengthVSAvoidweight

Core Design Contradiction:

StrengthVSWeight of moving object

Solution Approach 1:

The patent applies composite materials by combining a metallic substrate with a ceramic thermal barrier coating layer. This composite structure provides the strength of the metal substrate while the ceramic coating reduces weight and improves thermal durability, directly resolving the contradiction between strength and weight

Inventive Principle:

Principle #40Composite materials

2Strength

If superalloys are used for turbine engine components, then strength is improved, but thermal durability is limited

Engineering Contradiction:

ImprovestrengthVSAvoidthermal durability

Core Design Contradiction:

StrengthVSTemperature

Solution Approach 1:

The patent uses a composite structure with a metallic substrate and ceramic thermal barrier coating. The ceramic layer has superior thermal durability and protects the metal substrate from high-temperature degradation, enabling the component to withstand higher temperatures while maintaining strength

Inventive Principle:

Principle #40Composite materials

3Weight of moving object

If composite materials are used, then weight is reduced, but structural integrity may be compromised

Engineering Contradiction:

ImproveweightVSAvoidstructural integrity

Core Design Contradiction:

Weight of moving objectVSStrength

Solution Approach 1:

The patent employs a composite structure where a metallic substrate provides structural integrity and strength, while a ceramic thermal barrier coating provides thermal protection. The bonding between layers maintains structural integrity while the overall structure achieves weight reduction compared to solid superalloy components

Inventive Principle:

Principle #40Composite materials

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 composite airfoil assemblies provide lightweight, high-strength components that can withstand high temperatures, improving the efficiency and durability of turbine engines by reducing weight and maintaining structural integrity under extreme conditions.

Implementation Method 1

Turbine engine components, including stationary or rotating components, can include composite materials in some examples. Composite materials typically include a fiber-reinforced matrix and exhibit a high strength-to-weight ratio.

Methodology Applied

Scientific EffectComposite materials: Composite Materials

Implementation Method 2

Methodology Applied

Scientific EffectLamination: Lamination

Data Source

PatentUS12571314B2Composite airfoil assembly for a turbine engine

Publication Date: 2026.03.10 GENERAL ELECTRIC CO

AI summary

A composite airfoil assembly for a turbine engine includes an airfoil defining an airfoil interior, and an inner support structure at least partially located within the airfoil interior. The inner support structure can include a first core, a second core, and at least one pin. A laminate overlay surrounds at least a portion of the inner support structure.