Composite Centrifugal Compressor Wheel Fatigue
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Solution Overview
Problem
Cast centrifugal compressor wheels in turbochargers are prone to metal fatigue due to radial tensile loading, limiting their operational lifetime, and alternative materials like forged or wrought alloys are not economically viable for complex shapes.
Innovation Solution
A centrifugal compressor wheel made from a non-woven, discontinuous-fiber-filled polymer matrix composite material, which includes a hub and blade array formed from a thermoplastic or thermoset polymer matrix with dispersed fibers, providing enhanced strength and reduced rotational inertia.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If cast centrifugal compressor wheels are used, then manufacturing cost is reduced and complex shapes can be formed, but metal fatigue occurs due to radial tensile loading limiting operational lifetime
Solution Approach 1:
The patent applies composite materials by combining a polymer matrix with continuous fiber reinforcement to create a centrifugal compressor wheel that resists fatigue better than cast metal wheels while maintaining the ability to form complex shapes. The composite structure provides both durability and manufacturability.
2Reliability
If forged or wrought materials are used, then operational lifetime is improved by reducing fatigue, but manufacturing cost increases due to machining requirements for complex shapes
Solution Approach 1:
The patent uses composite materials that can be molded into complex shapes directly, eliminating the need for extensive machining while providing fatigue resistance. This approach achieves both improved reliability and ease of manufacture compared to traditional forged or wrought materials.
Solution Approach 2:
The patent changes the material parameters by using a polymer matrix with continuous fiber reinforcement instead of traditional metal alloys. This material parameter change enables direct molding of complex shapes while providing superior fatigue life, avoiding the need for costly machining operations.
3Weight of moving object
If lightweight metal alloys are used, then rotational inertia is reduced for rapid response, but susceptibility to fatigue increases
Solution Approach 1:
The patent uses composite materials that combine lightweight properties with enhanced fatigue resistance. The polymer matrix with continuous fiber reinforcement provides a structure that is both light and durable, overcoming the limitation of lightweight metal alloys that are prone to fatigue.
Data Source
AI summary
A centrifugal compressor wheel for a turbocharger is disclosed. The wheel includes an axially extending hub having an inlet end, an outlet end, an arcuate outer surface and a shaft bore. The wheel also includes a blade array disposed on the outer surface of the hub, the blade array comprising a plurality of circumferentially-spaced, radially and axially extending, arcuate centrifugal impeller blades disposed thereon; the hub and the blade array comprising a non-woven, discontinuous-fiber-filled, polymer matrix composite material.