Composite Airfoil Vane Spar Mounting for Load Transfer
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Solution Overview
Problem
Existing mounting systems for composite airfoils in gas turbine engines are not adequately robust or efficient in transferring loads from composite airfoils to metallic support structures, particularly in fan frames, while minimizing weight impact.
Innovation Solution
A vane mount system featuring spars extending radially from a bridge, fully encased within pockets of the composite airfoil, which are adhesively bonded and integral with the bridge, providing structural support and load transfer between composite airfoils and metallic structures within the fan frame.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If composite airfoils are mounted in metallic fan frames, then weight is reduced, but load transfer capability is insufficient
Solution Approach 1:
The spar is completely received within and encased by the composite airfoil pockets, creating a nested structure where the metallic spar is embedded inside the composite material. This nesting arrangement allows the composite airfoil to enclose and protect the spar while maintaining structural integrity for load transfer.
Solution Approach 2:
The invention uses composite materials for the airfoil structure combined with metallic spars for structural support. The composite airfoil is constructed from composite materials that provide weight reduction while the integrated metallic spar system provides enhanced load transfer capability, creating a hybrid composite-metal structure.
2Strength
If spars are completely encased within composite airfoil pockets, then structural integrity is enhanced, but manufacturing complexity increases
Solution Approach 1:
The spars are positioned and secured within the pockets before the composite airfoil is fully cured or finalized. This preliminary action allows the spars to be properly located and initially bonded, ensuring correct positioning and structural alignment before the composite material reaches its final state.
Solution Approach 2:
An adhesive bonding system is used as an intermediary between the metallic spar and the composite airfoil pockets. The adhesive layer facilitates the bond between the dissimilar materials (metal and composite), enabling effective load transfer while accommodating differences in thermal expansion and mechanical properties.
3Weight of moving object
If outlet guide vanes are made from composite materials, then weight is reduced, but durability under thermal and mechanical loads is compromised
Solution Approach 1:
The outlet guide vanes are constructed from composite materials that provide weight reduction while maintaining the necessary durability to withstand thermal and mechanical loads in the engine environment.
Solution Approach 2:
The composite airfoil is completely received within the metallic vane mount structure, creating a protected nested arrangement where the composite material is enclosed and shielded by the more thermally and mechanically resistant metallic structure.
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
Enhances the structural integrity and longevity of composite airfoils while maintaining a low weight, effectively transferring loads with minimal weight impact, thus improving the overall efficiency and durability of the fan frame assembly.
Implementation Method 1
The spars may be adhesively bonded to the composite airfoil within the one or more pockets.
Data Source
AI summary
A vane includes a composite airfoil having one or more pockets and one or more spars received therein respectively. The spars extending radially away from a bridge of a vane mount supporting airfoil. The spars may be integrally formed with the bridge. The spars may be adhesively bonded to the composite airfoil within the pockets. A passage may extend between an airfoil base and an airfoil tip. A gas turbine engine annular fan frame includes an annular row of the composite outlet guide vanes extending radially between and connecting radially inner and outer rings of the fan frame.