Composite Turbine Airfoil Leading Edge Protector Design
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Solution Overview
Problem
Existing composite airfoils in turbine engines face challenges in balancing leading edge protection with weight considerations, particularly in managing the overlap of protective coverings to ensure adequate bonding while maintaining flexibility for aerodynamic purposes.
Innovation Solution
The development of composite airfoils with a leading edge protector that overlaps sufficient portions of the airfoil to provide a strong bond while minimizing overlap to allow for flexibility, combined with a design that optimizes the relationship between leading length and chord length to achieve a balanced protection and weight profile.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the leading edge protector overlaps a larger portion of the airfoil, then the bond strength and protection reliability improve, but the weight increases and aerodynamic flexibility decreases
Solution Approach 1:
The leading edge protector is applied selectively to specific high-stress regions of the airfoil rather than uniformly across the entire surface. This localized application provides protection where most needed (leading edge and high-stress areas) while minimizing unnecessary material addition, thus balancing reliability improvement with weight control.
Solution Approach 2:
The patent applies a moderate overlap of the leading edge protector beyond the absolute minimum required, providing sufficient protection coverage without excessive material usage. This partial action approach ensures adequate bond strength and protection reliability while avoiding excessive weight gain that would occur with full coverage.
2Strength
If the leading edge protector overlaps a larger portion of the airfoil, then the bond strength improves, but the aerodynamic flexibility decreases
Solution Approach 1:
The leading edge protector is concentrated on the leading edge and high-stress regions where bond strength is most critical, rather than applying uniform coverage across the entire airfoil. This localized strengthening maintains aerodynamic flexibility in less critical areas while providing enhanced bond strength where needed.
Solution Approach 2:
The patent uses a moderate overlap extent that provides sufficient bond strength without excessive coverage. This partial action ensures adequate bonding in critical regions while preserving aerodynamic flexibility by avoiding over-protection in areas where it would constrain airflow or increase drag.
3Object-affected harmful factors
If the leading edge protector provides extensive coverage, then the protection against bird ingestion and erosion improves, but the weight increment increases
Solution Approach 1:
The leading edge protector is applied specifically to regions most vulnerable to bird ingestion and erosion (leading edge and high-stress areas) rather than providing uniform extensive coverage. This targeted approach maximizes protection effectiveness against harmful factors while minimizing unnecessary weight increment from material applied in less vulnerable areas.
Solution Approach 2:
The patent applies a moderate level of coverage that provides sufficient protection against bird ingestion and erosion without excessive material usage. This partial coverage approach ensures adequate protection in critical zones while controlling weight increment by avoiding over-protection in areas with lower exposure to harmful factors.
Data Source
AI summary
A turbine engine with an engine core defining an engine centerline and comprising a rotor and a stator. The turbine engine including a set of composite airfoils circumferentially arranged about the engine centerline and defining at least a portion of the rotor. An airfoil in the set of composite airfoils including a composite portion extending chordwise between a composite leading edge and a trailing edge and a leading edge protector coupled to the composite portion.