Composite Airfoil Spar-Root Assembly for Lightweight High-Temperature Strength
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Solution Overview
Problem
Existing turbine engine airfoils, particularly those made of composite materials, face challenges in achieving a high strength-to-weight ratio while maintaining performance in high-temperature environments, such as those found in gas turbine engines.
Innovation Solution
The development of a composite airfoil assembly using a triaxially braided carbon fiber spar/root assembly with integrated composite wedge retention, combined with preform shaping and an outer composite shell, which includes materials like carbon, glass, and Kevlar fibers, to enhance structural integrity and reduce weight.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If composite materials are used in turbine engine airfoils, then weight is reduced, but strength and durability in high-temperature environments deteriorates
Solution Approach 1:
The patent applies composite materials throughout the airfoil structure, including carbon fiber reinforced polymers and ceramic matrix composites, to achieve both weight reduction and high-temperature strength. The composite materials are engineered to maintain structural integrity in high-temperature environments while significantly reducing airfoil weight compared to traditional metallic materials.
Solution Approach 2:
Different regions of the airfoil are assigned different composite material compositions and structures optimized for their specific functional requirements. The leading edge and high-temperature zones use heat-resistant ceramic matrix composites, while other areas use carbon fiber reinforced polymers for optimal strength-to-weight ratio, creating locally optimized material properties throughout the structure.
2Weight of moving object
If composite materials are used in turbine engine airfoils, then weight is reduced, but temperature resistance deteriorates
Solution Approach 1:
Ceramic matrix composites and heat-resistant carbon fiber reinforced polymers are specifically selected and engineered to provide exceptional temperature resistance while maintaining lightweight characteristics. These composite materials can withstand the high-temperature environments of turbine engines better than traditional metals, while still providing significant weight reduction.
Solution Approach 2:
Heat-resistant composite materials are strategically applied to regions experiencing highest temperatures, such as the leading edge and areas exposed to hot gas flow. This localized application of temperature-resistant composites ensures adequate thermal protection while minimizing overall material usage and weight.
3Strength
If triaxially braided carbon fiber spar/root assembly is used, then structural integrity is enhanced, but manufacturing complexity increases
Solution Approach 1:
The spar and root assembly are merged into a single integrated triaxially braided carbon fiber structure, eliminating the need for separate components and their associated joints and fasteners. This integration simplifies the manufacturing process by requiring only one braiding operation and one curing cycle, while simultaneously enhancing structural integrity through continuous fiber reinforcement throughout the assembly.
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 assembly achieves a lighter weight without compromising performance, offering improved durability and temperature resistance, making it suitable for high-temperature sections of gas turbine engines.
Implementation Method 1
The outer composite shell is formed over the triaxially braided carbon fiber spar/root assembly with integrated composite wedge retention
Implementation Method 2
The composite airfoil assembly achieves a lighter weight without compromising performance, offering improved durability and temperature resistance
Data Source
AI summary
A composite airfoil assembly and method of forming includes a spar assembly with a spar core and a spar fiber layer at least partially surrounding the spar core, as well as a root assembly with a sleeve assembly carrying a set of spaced wedges defining at least one slot configured to receive a first end of the spar assembly.