Composite Gaspath Wall Wear Indication Layer
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Solution Overview
Problem
Composite laminates used in gas turbine engines are prone to erosion from airborne contaminants like water and hail, making it difficult to visually determine when structural components have worn beyond an acceptable service limit during inspection due to their uniform appearance.
Innovation Solution
Incorporating a visually contrasting wear indication layer within the composite material layers of gaspath traversing components, which is embedded inside the composite material and positioned interiorly relative to the outer edge surface, allowing for easier detection of wear through visual inspection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If composite laminates are used for structural components in the engine bypass gaspath, then the components gain structural strength and durability, but it becomes difficult to visually determine during inspection if the part is worn or eroded beyond acceptable service limits due to their uniform visual properties
Solution Approach 1:
The patent applies a wear indication layer with visual contrast (different color, texture, or reflectivity) embedded within the composite laminate structure. This layer remains hidden during normal operation but becomes visible when erosion reaches a predetermined depth, enabling easy visual detection of wear without compromising the structural integrity of the composite component.
2Weight of moving object
If composite laminates are used in the engine bypass gaspath, then the components benefit from weight reduction and corrosion resistance, but they become susceptible to erosion by airborne contaminants like water and hail with no visible indication of damage
Solution Approach 1:
The wear indication layer provides visual feedback when erosion occurs, allowing maintenance personnel to detect damage from airborne contaminants. The layer is positioned at a predetermined depth to indicate when erosion has reached critical levels, enabling timely maintenance while maintaining the weight and corrosion resistance benefits of composite materials.
Solution Approach 2:
The wear indication layer is pre-positioned at a specific depth within the composite laminate during manufacturing. This preliminary placement creates a built-in warning system that activates before structural integrity is compromised, allowing for preventive maintenance scheduling.
3Difficulty of detecting and measuring
If a wear indication layer is embedded within the composite material layers, then visual inspection becomes easier and maintenance timing can be determined, but the manufacturing process becomes more complex
Solution Approach 1:
The wear indication layer is nested within the composite laminate structure during the manufacturing process. This integration approach incorporates the indication layer as part of the multi-layer composite construction, allowing it to be manufactured simultaneously with the structural layers rather than as a separate post-processing step, thereby reducing overall manufacturing complexity.
Data Source
AI summary
A gaspath traversing component of a gas turbine engine comprises a wall having an outer edge surface and a thickness relative to the gaspath, the wall having a plurality of layers of composite materials forming the thickness. A wear indication layer is embedded within the plurality of layers of composite material, the wear indication layer being visually contrasting with the composite material. The wear indication layer is positioned interiorly of at least one layer of said plurality of layers of composite material relative to the outer edge surface. A method for attending to a gas traversing component of a gas turbine engine is also provided.