Variable-Thickness Composite Casing for Gas Turbine Retention Zones

Solution Overview

Problem

Existing methods for manufacturing gas turbine casings with composite materials are limited by the weaveability of 3D woven textures, which restricts the maximum amplitude of extra thickness in retention zones and the warp-weft ratio, making it difficult to achieve desired mechanical properties while minimizing mass.

Innovation Solution

A method involving three-dimensional or multilayer weaving of fibrous textures with interposed textile strips or aerated materials between layers, allowing for controlled variation in thickness and warp-weft ratio to form retention zones with enhanced mechanical performance and reduced mass.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Volume of moving object

If the size of warp threads is increased to thicken the fibrous reinforcement in the retention zone, then the excess thickness and retention capability are improved, but the weaveability of the 3D woven texture is exceeded and the warp-to-weft ratio becomes uncontrolled

Engineering Contradiction:

Improveexcess thickness of retention zoneVSAvoidweaveability of fibrous texture

Core Design Contradiction:

Volume of moving objectVSEase of manufacture

Solution Approach 1:

The fibrous reinforcement is divided into multiple discrete layers of 3D woven textures, with each layer having controlled thickness. The retention zone is formed by stacking a greater number of these standardized layers rather than using single layers with excessively thick warp threads, thus maintaining weaveability while achieving the required excess thickness.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Instead of increasing thickness within a single layer by enlarging warp threads (2D approach), the invention achieves the required thickness by stacking multiple layers in the radial direction (3D approach). This dimensional transition allows control of the warp-to-weft ratio in each layer while accumulating the necessary excess thickness through layer multiplication.

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

2Volume of moving object

If the size of warp threads is increased to achieve desired excess thickness, then the retention zone amplitude is improved, but the warp-to-weft ratio exceeds the maximum admissible threshold

Engineering Contradiction:

Improveexcess thickness of retention zoneVSAvoidwarp-to-weft ratio control

Core Design Contradiction:

Volume of moving objectVSManufacturing precision

Solution Approach 1:

The fibrous reinforcement is divided into multiple discrete layers of 3D woven textures, with each layer having controlled thickness. The retention zone is formed by stacking a greater number of these standardized layers rather than using single layers with excessively thick warp threads, thus maintaining weaveability while achieving the required excess thickness.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Instead of increasing thickness within a single layer by enlarging warp threads (2D approach), the invention achieves the required thickness by stacking multiple layers in the radial direction (3D approach). This dimensional transition allows control of the warp-to-weft ratio in each layer while accumulating the necessary excess thickness through layer multiplication.

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

3Weight of moving object

If composite material is used to reduce casing mass, then the overall mass is reduced, but the ability to achieve high excess thickness in retention zones is limited by weaving constraints

Engineering Contradiction:

Improveoverall mass of casingVSAvoidexcess thickness of retention zone

Core Design Contradiction:

Weight of moving objectVSVolume of moving object

Solution Approach 1:

The fibrous reinforcement is divided into multiple discrete layers of 3D woven textures, with each layer having controlled thickness. The retention zone is formed by stacking a greater number of these standardized layers rather than using single layers with excessively thick warp threads, thus maintaining weaveability while achieving the required excess thickness.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Instead of increasing thickness within a single layer by enlarging warp threads (2D approach), the invention achieves the required thickness by stacking multiple layers in the radial direction (3D approach). This dimensional transition allows control of the warp-to-weft ratio in each layer while accumulating the necessary excess thickness through layer multiplication.

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

Data Source

PatentEP3393764B1Lighter-weight casing made of composite material and method of manufacturing same

Publication Date: 2024.02.14 SAFRAN AIRCRAFT ENGINES SAS

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AI summary

A method of manufacturing a variable-thickness composite-material casing (100) for a gas turbine, comprises: – using three-dimensional or multi-layer weaving to create a fibrous texture (140) in the form of a strip, – winding the fibrous texture (140) in several superposed layers (141, 142, 143, 144) onto a mandrel having a profile corresponding to that of the casing that is to be manufactured, so as to obtain a fibrous preform of a shape corresponding to that of the casing that is to be manufactured, – densifying the fibrous preform using a matrix. During the winding of the fibrous texture (140) onto the mandrel, a textile strip (150) is interposed between the adjacent turns of the fibrous texture, the textile strip (150) having a width smaller than the width of the fibrous texture (140) and delimiting a retention zone of the casing.