Composite Material Marking for Gas Turbine Identification
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Solution Overview
Problem
Conventional marking techniques for uniquely identifying components in gas turbine engines, such as 2D dot matrix marking, are ineffective due to distortion, alteration, or erosion caused by heat and high-velocity air, making it difficult to read or scan ceramic matrix composite (CMC) or organic matrix composite (OMC) components.
Innovation Solution
Creating a unique pattern on designated surface areas of components formed from fiber materials, such as CMC or OMC, using the inherent properties of the fiber materials and tows, which are scanned to identify the components, eliminating the need for additional marking and providing a permanent identification method.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional marking techniques (2D dot matrix marking) are used to identify components, then marking can be applied to components, but the marking is distorted, altered, or eroded by heat and high-velocity air, making it difficult to read or scan
Solution Approach 1:
The fiber material itself serves as the marking medium. The unique pattern is created by the inherent properties of the fiber material and tow during the forming process, eliminating the need for separate marking applications. The fiber material's own structure provides the identification pattern that survives the harsh environment.
Solution Approach 2:
The invention changes the state of the marking from a surface-applied 2D pattern to a three-dimensional pattern embedded within the fiber material structure. By incorporating the pattern into the bulk material properties during forming, the marking becomes resistant to surface-level environmental degradation from heat and air flow.
2Reliability
If additional marking is applied to fiber material components, then identification can be achieved, but the marking process adds complexity and the marking remains vulnerable to environmental degradation
Solution Approach 1:
The invention merges the identification function with the structural material itself. The unique pattern is created from the properties of the fiber material and tow during the forming process, combining the structural and identification functions into a single integrated feature rather than separate applied markings.
Solution Approach 2:
The unique pattern is created during the forming process itself, before the component enters service. By incorporating the identification pattern into the material structure during manufacturing, the marking is established in advance and remains permanent throughout the component's service life, eliminating the need for subsequent marking steps.
3Reliability
If conventional marking is used on CMC or OMC components, then marking can be applied, but the marking is easily worn or altered in harsh engine environments
Solution Approach 1:
The invention uses composite fiber material structures to create the marking. The unique pattern is formed by the arrangement and properties of fibers within the composite material, leveraging the inherent durability and heat resistance of the composite structure to protect the identification pattern from wear and alteration.
Solution Approach 2:
The invention applies different structural properties to different regions of the fiber material. The unique pattern is created by varying the local arrangement or properties of fibers in specific areas, allowing the marking to be embedded within the material structure itself rather than applied as a surface coating that could be worn away.
Data Source
AI summary
An example method for manufacturing a component of a gas turbine engine is provide. The method includes forming a tow of filaments of a fiber material. The method further includes weaving the tow together with other tows to form a sheet of the fiber material. The method further includes forming the component from the sheet of fiber material, the component comprising a designated surface area having a unique pattern created from properties of the fiber material.