Composite Blade Manufacturing to Reduce Ply Distortion and Waste
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Solution Overview
Problem
Gas turbine engine blades face challenges in resisting damage from foreign object ingestion and require materials that minimize material waste and undulations during manufacturing.
Innovation Solution
A method involving the laying up of pre-impregnated composite material between pressure plates, followed by vacuum bagging and consolidation to form fiber-reinforced blades, reducing material waste and improving laminate quality.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If a large volume of material is used in the root section during manufacturing, then ply distortion is prevented during the cure cycle, but significant material waste is generated
Solution Approach 1:
The method performs preliminary consolidation of the root section material before the final cure cycle. By pre-consolidating the root section with a first consolidation pressure and then applying a second consolidation pressure during curing, the process ensures proper ply alignment and prevents distortion without requiring excessive material volume, thereby reducing waste.
2Shape
If filler plies are used to build up airfoil geometry, then part of the geometry is formed, but undesired undulations in the laminate architecture are generated
Solution Approach 1:
The method changes the consolidation pressure parameters during the manufacturing process. By applying a first consolidation pressure to pre-consolidate the root section and then a second consolidation pressure during the cure cycle, the process achieves smooth airfoil geometry without the need for filler plies that cause undulations, maintaining laminate architecture uniformity.
3Reliability
If titanium alloys or fiber composites are used to construct fan or compressor blades, then damage resistance is improved, but manufacturing complexity increases
Solution Approach 1:
The manufacturing process is segmented into distinct phases: pre-consolidation of the root section, vacuum bagging, and final curing. By dividing the complex composite manufacturing into manageable stages with specific consolidation pressures applied at each phase, the process maintains damage resistance while reducing overall manufacturing complexity and improving control.
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
This method enhances the resistance of blades to damage while minimizing material waste and improving laminate architecture, ensuring efficient production of composite blades.
Implementation Method 1
vacuum bagging the pre-impregnated composite structure between a first pressure plate and a second pressure plate
Implementation Method 2
consolidating and curing the pre-impregnated composite structure to form a fiber-reinforced composite structure
Data Source
AI summary
A method of manufacturing composite blades comprises: laying up a pre-impregnated composite material to form a pre-impregnated composite structure; vacuum bagging the pre-impregnated composite structure between a first pressure plate and a second pressure plate; consolidating and curing the pre-impregnated composite structure to form a fiber-reinforced composite structure; and machining an overlap portion of the fiber-reinforced composite structure to form a first fiber-reinforced composite blade and a second fiber-reinforced composite blade.