Composite Duct Metallic Flange Assembly
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Solution Overview
Problem
Existing gas turbine engine ducts face challenges in combining metallic and non-metallic materials effectively for structural reinforcement, sealing, and reduced manufacturing complexity, particularly in achieving lightweight, cost-effective, and turbulence-minimizing designs.
Innovation Solution
A duct design featuring a metallic flange sandwiched between two non-metallic fiber composite members, secured by resin, with the metallic flange providing structural reinforcement and a smooth surface for airflow, and a method involving assembly, bagging, and autoclaving for manufacturing, allowing for reduced manufacturing steps and increased automation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If traditional metal ducts are used, then structural strength and mounting functionality are ensured, but weight increases and manufacturing costs rise
Solution Approach 1:
The duct employs a hybrid composite structure combining non-metallic members (carbon fiber reinforced polymer or similar composite materials) with a metallic flange member. The non-metallic members provide lightweight structural strength while the metallic flange provides mounting functionality, achieving weight reduction without sacrificing overall structural performance
Solution Approach 2:
The metallic flange member is strategically positioned only at the flange portion where mounting and structural reinforcement are needed, rather than using metal throughout the entire duct. This localized application of metallic material maintains mounting functionality and critical structural strength while minimizing weight
2Weight of moving object
If composite layup processes are used, then weight is reduced, but manufacturing complexity increases
Solution Approach 1:
The duct is divided into separate modular components: non-metallic members, metallic flange member, and seal member. These segments can be manufactured independently using optimized processes for each material type, then assembled together, reducing the overall manufacturing complexity compared to creating a monolithic composite structure
Solution Approach 2:
The seal member is integrated into the assembly by being received within grooves of the non-metallic members and metallic flange, combining sealing functionality with the structural components. This integration reduces the number of separate parts and assembly steps while maintaining effective sealing
3Strength
If metallic and non-metallic materials are combined, then structural reinforcement is achieved, but manufacturing difficulty increases
Solution Approach 1:
The duct is divided into separate modular components: non-metallic members, metallic flange member, and seal member. These segments can be manufactured independently using optimized processes for each material type, then assembled together, reducing the overall manufacturing complexity compared to creating a monolithic composite structure
Solution Approach 2:
The seal member acts as an intermediary element that facilitates the connection between non-metallic members and the metallic flange. This intermediary component enables effective joining of dissimilar materials while maintaining sealing integrity and reducing manufacturing difficulty
4Object-generated harmful factors
If smooth surfaces are created for airflow, then turbulence is reduced, but manufacturing precision requirements increase
Solution Approach 1:
The non-metallic members provide inherently smooth external surfaces that minimize turbulence and drag. The composite material structure naturally produces the required surface quality without demanding extreme manufacturing precision, as the material itself can be formed to the required smoothness
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 solution enhances structural integrity, reduces manufacturing costs, and minimizes turbulence and drag by using a composite material system that is lighter and more cost-effective than traditional metal ducts, while maintaining the strength and mounting functionality of metallic components.
Implementation Method 1
the first non-metallic member flange portion and the second non-metallic member flange portion are secured to the flange by resin
Implementation Method 2
heating the bagged assembly
Implementation Method 3
the heating comprises autoclaving
Data Source
Figure 1
Figure 2
Figure 3
AI summary
A duct (78) has: a first non-metallic member (86) extending between a first end and a second end, at least at the first end having an outwardly-projecting flange portion (94); a metallic flange member (90) having a sleeve (180) extending between a first end and a second end and a flange (140) extending outward from the sleeve and having a first face (144) and a second face (142); and a second non-metallic member (88) extending between a first end and a second end having an outwardly-projecting flange (150) portion, the first non-metallic member flange portion mounted to the flange first face and the second non-metallic member flange portion mounted to the flange second face.