Composite Airfoil Segmented Skin and Core Manufacturing
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Solution Overview
Problem
Existing methods for manufacturing composite airfoils for gas turbine engines lack flexibility in material and process selection, as they typically require co-molding of composite cores and skins, limiting quality inspection, automation, and optimization of separate fabrication processes.
Innovation Solution
The method involves forming fully cured composite skins and a removable dry or polymer-impregnated composite core separately, allowing for independent optimization of materials and processes, with optional adhesive layers and a metal sheath for enhanced bonding and protection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If co-molding of composite cores and skins is used, then structural integrity is achieved, but flexibility in material and process selection is limited
Solution Approach 1:
The composite airfoil manufacturing process is segmented into separate fabrication of composite skins and composite core, allowing independent optimization of materials and processes for each component before final assembly through adhesive bonding
Solution Approach 2:
Composite skins are pre-formed and fully cured before the composite core is fabricated, enabling quality inspection and process optimization to be performed on each component independently before final assembly
2Manufacturing precision
If co-curing of preform core and prepreg fiber layers is used, then monolithic structure is achieved, but quality inspection and process optimization are limited
Solution Approach 1:
The manufacturing process is divided into separate stages for skin fabrication and core fabrication, allowing quality inspection to be performed on fully cured skins before core insertion and assembly
Solution Approach 2:
Composite skins are completely formed and cured in advance before core fabrication begins, enabling thorough quality inspection and non-destructive testing to be performed on skins independently
3Productivity
If separate fabrication of skins and core is used, then process optimization is improved, but structural integrity during assembly must be ensured
Solution Approach 1:
Adhesive layers are introduced as intermediary bonding agents between the composite skins and composite core, providing strong structural connection while allowing independent fabrication and curing of each component
Solution Approach 2:
The airfoil is segmented into separately fabricated skins and core that are subsequently bonded together through adhesive layers, enabling parallel production and process optimization
Data Source
Figure 1A~1B
Figure 2~3
AI summary
An intermediate-manufactured composite airfoil (10) includes first and second composite skins (12,14) each having a plurality of fibers (16) in a polymer matrix (18). A composite core (20) is removably located between the first and second composite skins (12,14). The composite core (20) includes a dry, three-dimensional, woven fiber network (22) or, alternatively, a three-dimensional, woven fiber network (22) in a fully cured polymer matrix (24).