Composite Airfoil Assembly with Recessed Cladding for Turbine Engines
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Solution Overview
Problem
Turbine engine components, particularly airfoils, face challenges in achieving a balance between weight reduction, strength, stiffness, and aerodynamic efficiency due to the limitations of traditional materials in high-temperature regions.
Innovation Solution
A composite airfoil assembly is designed with a woven core and laminate skin, incorporating recesses for cladding to enhance stiffness and strength while maintaining a smooth outer surface for improved aerodynamics, utilizing materials like carbon or glass fibers with thermoplastic polymers for enhanced properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If composite materials are used to reduce weight, then weight is reduced, but strength and stiffness may be insufficient in high-temperature regions
Solution Approach 1:
The patent employs a hybrid composite structure combining carbon fiber reinforced plastic (CFRP) and glass fiber reinforced plastic (GFRP). The CFRP provides high strength and stiffness, while the GFRP offers cost-effectiveness and good corrosion resistance. This composite approach achieves weight reduction while maintaining sufficient strength in high-temperature regions through material selection and structural design.
Solution Approach 2:
The patent applies different composite materials to different regions of the airfoil based on local requirements. High-strength CFRP is used in critical high-temperature regions, while GFRP is used in lower-stress areas. This local differentiation optimizes the strength-to-weight ratio by concentrating high-performance materials where most needed.
2Strength
If cladding is added to enhance stiffness and strength, then strength and stiffness are improved, but aerodynamic efficiency may deteriorate due to surface irregularities
Solution Approach 1:
The patent integrates the cladding structure within recesses of the airfoil skin, creating a nested configuration where the cladding is partially embedded rather than protruding. This nesting approach allows the cladding to provide structural reinforcement while minimizing its impact on the external aerodynamic surface, thereby reducing drag.
Solution Approach 2:
The cladding is strategically positioned only in specific regions where additional stiffness and strength are required, such as high-stress areas, rather than covering the entire airfoil surface. This localized application maintains aerodynamic efficiency in regions where the cladding is not needed while providing structural enhancement where critical.
3Object-generated harmful factors
If a smooth outer surface is maintained for aerodynamic efficiency, then aerodynamic drag is reduced, but structural reinforcement options are limited
Solution Approach 1:
The patent incorporates reinforcement cladding within recesses carved into the airfoil skin, allowing structural strengthening without external protrusions. The nested configuration ensures the reinforcement is hidden within the skin geometry, preserving the smooth external surface needed for aerodynamic efficiency while providing the necessary structural support.
Solution Approach 2:
The use of high-performance composite materials allows the airfoil to achieve both aerodynamic smoothness and structural strength. The composite skin itself provides substantial strength, reducing the need for external cladding, and any necessary reinforcements can be integrated within the composite structure without disrupting the external surface.
Data Source
AI summary
A composite airfoil assembly for a turbine engine. The composite airfoil assembly has an airfoil outer surface defining opposing pressure and suction sides, which extend between a leading edge and a trailing edge. The composite airfoil assembly includes a composite airfoil having a woven core and a skin applied to at least a portion of a core exterior. The composite airfoil assembly also includes a cladding coupled to a skin outer surface where at least one edge or portion of the cladding is located adjacent at least one of the trailing edge, a root, or a tip, wherein the cladding includes a tapered portion.