Composite Turbine Fan Blade Platform with Integrated Gaskets
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Solution Overview
Problem
Adhesively bonding gaskets to fan blade platforms in turbine engine fans is a complex and time-consuming process that often results in gaskets becoming unstuck, leading to aerodynamic performance losses due to recirculating air.
Innovation Solution
A method of fabricating composite material fan blade platforms with integrated gaskets using three-dimensional weaving to create a single-piece fiber blank, where gaskets are positioned and secured within the fiber preform before resin injection, eliminating the need for adhesive bonding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If gaskets are adhesively bonded to the platform, then sealing is provided, but the bonding process is complicated and time-consuming
Solution Approach 1:
The gasket and platform are merged into a single integrated component through co-molding. The gasket is molded directly onto the platform during the same injection molding process, eliminating the need for separate adhesive bonding operations. This combining of components resolves the technical contradiction by providing reliable sealing while simplifying the manufacturing process.
Solution Approach 2:
The gasket is pre-positioned in the mold cavity before the injection molding process begins. This preliminary positioning ensures that the gasket is correctly located on the platform before resin injection, eliminating the need for post-molding adhesive bonding and reducing both process complexity and time.
2Reliability
If gaskets are adhesively bonded to the platform, then sealing is provided, but the process requires a large amount of time
Solution Approach 1:
The gasket and platform are manufactured as a single integrated part through co-molding, combining two separate manufacturing operations into one. This eliminates the sequential steps of molding the platform, applying adhesive, and bonding the gasket, thereby significantly reducing manufacturing time and improving productivity while maintaining sealing reliability.
Solution Approach 2:
The injection molding process continuously forms both the platform and gasket in a single uninterrupted operation. The resin is injected and solidifies to create the integrated component, eliminating idle time between separate bonding operations and maintaining continuous productive action throughout the manufacturing process.
3Reliability
If gaskets are adhesively bonded to the platform, then sealing is provided, but the gaskets rapidly become unstuck
Solution Approach 1:
The gasket and platform are merged into a single monolithic component through co-molding, where the resin bonds the gasket to the platform at the molecular level during solidification. This creates a permanent, irreversible connection that eliminates the risk of the gasket becoming unstuck, thereby ensuring long-term sealing reliability without relying on adhesive bonds that can fail over time.
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 method ensures gaskets are directly fastened to the platform, avoiding the drawbacks of adhesive bonding and providing a durable seal, thus enhancing aerodynamic performance and reducing manufacturing complexity.
Implementation Method 1
using three-dimensional weaving to make a single-piece fiber blank with a plurality of longitudinal yarn layers extending in a direction corresponding to a longitudinal direction of the base of the platform and interlinked by yarns of a plurality of transverse yarn layers
Implementation Method 2
injecting resin into the injection mold
Implementation Method 3
heating the injection mold to solidify the resin
Data Source
AI summary
There is provided a method of fabricating a blade platform out of composite material with integrated gaskets for a turbine engine fan, the platform including a base and a stiffener, the method including using three-dimensional weaving to make a single-piece fiber blank with a plurality of longitudinal yarn layers extending in a direction corresponding to a longitudinal direction of the base of the platform; shaping the fiber blank to form a fiber preform having a first portion forming a base preform and a second portion forming a stiffener preform; positioning platform gaskets at side margins of the first portion of the fiber preform forming a base preform; placing the fiber preform with the gaskets in an injection mold; injecting resin into the injection mold; compacting the assembly; heating the injection mold to solidify the resin; and unmolding the resulting platform.