Composite Inlet Guide Vane Design for Corrosion and Fatigue Resistance
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Solution Overview
Problem
Current inlet guide vanes made of GTD 450 precipitation-hardened stainless steel suffer from wear and corrosion pitting-induced high cycle fatigue in the spindle area and corrosion pitting in the airfoil portion, leading to in-service distress.
Innovation Solution
A composite vane design utilizing a fiberglass epoxy inner core for high static and fatigue strength, with carbon epoxy fabric for bi-directional stiffness and an outer aluminum sheath for foreign object damage and corrosion resistance, strategically placed to address specific challenges.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If GTD 450 precipitation-hardened stainless steel is used for the entire vane, then strength and durability are improved, but cost increases and corrosion resistance in certain areas remains insufficient
Solution Approach 1:
The patent applies different materials to different regions of the vane based on specific performance requirements. The airfoil portion uses fiberglass epoxy composite for cost-effectiveness and adequate strength, while the spindle area (which experiences wear and corrosion pitting-induced fatigue) uses GTD 450 stainless steel for enhanced durability. This localized material assignment resolves the contradiction by providing strength only where needed rather than uniformly across the entire component.
Solution Approach 2:
The patent employs a composite construction combining fiberglass epoxy and GTD 450 stainless steel in a single vane structure. The fiberglass epoxy provides baseline strength and cost benefits, while the stainless steel reinforcement addresses specific corrosion and fatigue issues in the spindle area. This composite approach resolves the contradiction by integrating materials with complementary properties to achieve both strength and cost-effectiveness.
2Duration of action of stationary object
If GTD 450 precipitation-hardened stainless steel is used for the entire vane, then durability is improved, but corrosion resistance in the airfoil portion is insufficient
Solution Approach 1:
The patent identifies that the airfoil portion has specific corrosion vulnerabilities and addresses this by applying a corrosion-resistant coating or cladding material specifically to the airfoil surfaces. The fiberglass epoxy core provides structural durability, while the outer corrosion-resistant layer protects against environmental degradation. This localized protection strategy resolves the contradiction by providing corrosion resistance precisely where it is needed without requiring expensive stainless steel throughout the entire vane.
3Ease of manufacture
If fiberglass epoxy is used for the airfoil portion, then cost is reduced and static strength is improved, but bi-directional stiffness is insufficient
Solution Approach 1:
The patent uses a composite structure where fiberglass epoxy provides the primary structural matrix for the airfoil portion, offering cost-effectiveness and adequate static strength. Additionally, carbon fiber reinforcement is embedded within the fiberglass epoxy to provide enhanced bi-directional stiffness. This composite approach resolves the contradiction by combining materials with complementary properties - the fiberglass epoxy delivers cost and static strength benefits, while the carbon fiber reinforcement addresses the stiffness requirement.
Data Source
AI summary
A composite vane includes an airfoil portion having an inner core composed primarily of fiberglass epoxy; a carbon epoxy fabric located outward of the inner core; a relatively thin layer of fiberglass epoxy, and an outer metal sheath.