Composite Turbine Airfoils Balancing Bird-Strike Protection And Weight

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Solution Overview

Problem

Composite airfoils in turbine engines face challenges in balancing weight and protection, particularly in extreme loading conditions such as bird ingestion, where the leading edge requires sufficient protection without compromising aerodynamic flexibility and efficiency.

Innovation Solution

Designing composite airfoils with a metallic leading edge protector that overlaps with the composite airfoil to provide strength and protection, while minimizing weight increase, using methods like additive manufacturing to optimize the balance between protection and flexibility.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If a metallic leading edge protector is added to the composite airfoil, then the strength and protection against bird ingestion is improved, but the weight increases

Engineering Contradiction:

Improveleading edge protectionVSAvoidairfoil weight

Core Design Contradiction:

StrengthVSWeight of moving object

Solution Approach 1:

The airfoil is divided into two distinct parts: a composite airfoil section and a separate metallic leading edge protector. This segmentation allows each component to be optimized independently - the composite material provides lightweight structural support while the metallic protector provides concentrated protection at the critical leading edge area, minimizing overall weight increase.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The metallic leading edge protector is applied locally only where protection is most needed - at the leading edge of the airfoil. This localized approach ensures that the protective feature is concentrated in the area most susceptible to bird ingestion and extreme loading, rather than adding protective material throughout the entire airfoil structure, thus minimizing unnecessary weight.

Inventive Principle:

Principle #3Local quality

2Strength

If a metallic leading edge protector is added to the composite airfoil, then the protection against extreme loading is improved, but the aerodynamic flexibility is compromised

Engineering Contradiction:

Improveprotection against extreme loadingVSAvoidaerodynamic flexibility

Core Design Contradiction:

StrengthVSAdaptability or versatility

Solution Approach 1:

By separating the protective function from the aerodynamic surface, the metallic leading edge protector can be designed to provide strength without interfering with the aerodynamic contours of the composite airfoil. The protector follows the aerodynamic shape while providing structural reinforcement, allowing the aerodynamic surface to maintain its flexibility and contoured design.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The metallic protector is applied locally at the leading edge where extreme loading occurs, while the rest of the airfoil maintains its composite construction with inherent flexibility. This localized protection allows the majority of the airfoil surface to retain its aerodynamic flexibility and ability to adapt to flight conditions.

Inventive Principle:

Principle #3Local quality

Data Source

PatentUS20260009399A1Turbine engine with composite airfoils

Publication Date: 2026.01.08 GENERAL ELECTRIC CO

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.