Composite Gas Turbine Casing Assembly via Platform Insertion
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Solution Overview
Problem
Gas turbine engine exhaust casings are typically made of metal, resulting in a heavy component that increases fuel consumption due to their weight.
Innovation Solution
A method of fabricating a casing using composite materials, comprising an outer and inner shroud made of ceramic matrix composite (CMC) with radially extending arms, where the shrouds and arms are assembled by inserting platforms into openings, and held together through brazing or mechanical connection, allowing for a lighter and more efficient structure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a metal casing is used for the gas turbine engine exhaust, then the casing provides sufficient structural strength and durability, but the weight of the casing increases significantly
Solution Approach 1:
The patent applies composite materials (specifically ceramic matrix composites or CMCs) to manufacture the exhaust casing components including the outer shroud, inner shroud, and casing arms. These composite materials provide sufficient structural strength and thermal resistance while significantly reducing the weight compared to traditional metal alloys, directly resolving the contradiction between strength and weight.
2Weight of moving object
If a composite material casing is used, then the weight is reduced significantly, but the manufacturing complexity and assembly process become more challenging
Solution Approach 1:
The exhaust casing is divided into separate modular components including an outer shroud, an inner shroud, and multiple casing arms, all manufactured independently using composite materials. This segmentation allows each component to be manufactured separately using optimized composite processing techniques, then assembled together, thereby reducing the overall manufacturing complexity while achieving weight reduction.
Solution Approach 2:
The patent integrates the outer shroud, inner shroud, and casing arms into a unified composite material casing structure through standardized connection interfaces. This merging of multiple components into a coordinated assembly simplifies the overall manufacturing process by using consistent material properties and connection methods across all parts.
3Ease of manufacture
If traditional metal casing components are used, then the assembly process is straightforward, but the fuel consumption increases due to the heavy weight
Solution Approach 1:
By using composite materials for the exhaust casing, the weight is reduced significantly (density ratio of about 4 compared to metal alloys), which directly reduces the fuel consumption of the aircraft. The composite components are designed with standardized connection interfaces that maintain assembly simplicity despite the material change.
Solution Approach 2:
The segmented design of the composite casing with standardized connection interfaces between outer shroud, inner shroud, and casing arms maintains assembly simplicity comparable to traditional metal casings, while the weight reduction from composite materials leads to lower fuel consumption.
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 material casing is significantly lighter than a metal casing, simplifies assembly, and reduces weight-related fuel consumption while maintaining structural and aerodynamic functionality.
Implementation Method 1
each shroud is made from a fiber preform obtained by winding a plurality of superposed layers of a fiber texture onto a mandrel, the fiber preform being densified with a matrix
Implementation Method 2
The casing arms are held assembled with an outer shroud and with an inner shroud by brazing, by co-densification, or by mechanical connection of their respective platforms in the openings of the shrouds
Data Source
AI summary
A method of fabricating a composite material casing for a gas turbine engine, the method including making an outer shroud including a platform and a flange, making an inner shroud of smaller diameter than the outer shroud and including a platform and a flange, making a plurality of casing arms, each including a blade that is terminated at each radial end by a respective platform, arranging a plurality of openings in the respective platforms of the shrouds, each opening serving to receive a platform of a casing arm, and assembling the casing arms with the outer shroud and with the inner shroud by inserting the platforms of the casing arms in the openings of the shrouds. A composite material casing is obtained by such a method.