3D Woven Composite Fan Platform with Metal Reinforcement
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Solution Overview
Problem
Current manufacturing processes for aircraft turbomachine fan platforms are complex, costly, and unsatisfactory due to the use of metal platforms with composite blades, which face issues of wear and weakening, and existing composite platforms are heavy, complex to produce, and costly to manufacture.
Innovation Solution
A method involving three-dimensional weaving of fibers to create a preform, separating fibers to insert a metal reinforcement, and injecting thermosetting or thermoplastic resin to form a lightweight, stiff, and durable composite platform with an integrated fixing tab, eliminating the need for mechanical assembly and reducing production costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If metal platforms are used with composite blades, then structural strength and durability are improved, but wear and weakening of the blades occurs due to metal-composite contact
Solution Approach 1:
The platform is manufactured entirely from composite materials (carbon fibers and resin) matching the blade material, eliminating metal-composite contact. This homogeneous material composition prevents wear and galvanic corrosion while maintaining structural strength through optimized fiber architecture and resin bonding.
Solution Approach 2:
The platform utilizes composite materials (carbon fibers woven in 3D architecture with thermosetting or thermoplastic resin) to replace metal entirely. The composite construction provides both the necessary mechanical strength and compatibility with composite blades, eliminating the wear problem inherent in metal-composite interfaces.
2Reliability
If composite platforms are manufactured using current technologies, then blade compatibility is improved, but manufacturing complexity and production costs increase significantly
Solution Approach 1:
A preform structure is created beforehand with fibers arranged in a 3D woven architecture that pre-defines the platform's geometric and mechanical properties. This preliminary fiber arrangement allows subsequent resin injection to complete the manufacturing process in a single step, dramatically simplifying production compared to traditional multi-step composite manufacturing.
Solution Approach 2:
The traditional mechanical assembly process (multiple manufacturing steps, tooling, and assembly operations) is replaced by a resin injection process that consolidates platform formation into a single casting operation. The preformed fiber structure guides the resin to automatically form the final geometry, eliminating complex mechanical manufacturing steps.
3Reliability
If composite platforms are manufactured using current technologies, then blade compatibility is improved, but production time and manufacturing costs remain high
Solution Approach 1:
The 3D woven fiber preform is prepared in advance with precise geometric configuration, allowing the resin injection step to proceed rapidly without requiring complex in-situ fiber arrangement. This preliminary structuring of the reinforcement dramatically reduces the actual manufacturing cycle time while maintaining high blade compatibility.
Solution Approach 2:
The manufacturing process is replaced from mechanical assembly operations (which are time-consuming and labor-intensive) to a resin injection casting process. This substitution enables rapid production of complex composite platforms in a single continuous operation, significantly improving productivity and reducing costs.
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 results in a lighter, more durable composite platform with reduced production complexity and cost, improved stiffness, and extended lifespan, while maintaining aerodynamic performance and safety by integrating a metal reinforcement within the composite structure.
Implementation Method 1
injecting a thermosetting or thermoplastic resin into the preform so as to form said wall and to secure the reinforcement to this wall
Implementation Method 2
producing a preform by three-dimensional weaving of fibers, this preform having an elongated shape along an elongation axis
Data Source
Figure 1
Figure 2
Figure 3~4
AI summary
Method for manufacturing a composite platform (30) for an aircraft turbine engine fan, this platform having a wall (32) of elongate shape that is configured to extend between two fan blades (3), this wall having an aerodynamic external face (32a) and an internal face (32b) on which a fixing tab (34) configured to be fixed to a fan disc (2) is disposed, characterized in that it comprises the steps of: a) producing a preform (42) by three-dimensionally weaving of fibres, b) unbinding some of the fibres of the preform so as to detach at least one longitudinal layer of fibres (42a) from the rest (42b) of the preform, c) inserting a metal reinforcement (36) between this layer and the rest of the preform, and d) injecting a resin into the preform so as to form said wall and secure the reinforcement to this wall.