Gas Turbine Composite Shield Flush Interface
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Solution Overview
Problem
Modern gas turbine engines face challenges in protecting composite components from foreign object impact damage and surface erosion, with existing methods being complex and time-consuming, and struggling to maintain a flush interface between shields and composite components without compromising aerodynamic performance.
Innovation Solution
A method involving the application of a thermoplastic polymer sheet over a composite body, followed by pressing a shield into the sheet to deform the polymer and create a flush interface, reducing the thickness of the polymer layer in the shielded region for improved impact resistance and erosion resistance in the unshielded region.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If shields are attached to composite components using conventional methods, then impact resistance is improved, but the manufacturing process becomes complex and time-consuming
Solution Approach 1:
The patent combines the shield attachment process with the composite component manufacturing process into a single integrated operation. The shield is positioned on the composite preform before resin injection, allowing both components to be manufactured and assembled simultaneously rather than as separate steps, thereby reducing manufacturing complexity while maintaining impact resistance
Solution Approach 2:
The shield is pre-positioned on the composite preform before the resin injection and curing process. This preliminary placement ensures the shield is correctly positioned and integrated into the manufacturing flow, eliminating the need for separate attachment operations and reducing overall process complexity
2Strength
If shields are attached to composite components, then impact resistance is improved, but achieving a flush interface becomes difficult
Solution Approach 1:
By merging shield attachment with composite manufacturing, the shield and composite structure are formed together as an integrated unit. The resin injection process flows around the shield, naturally forming a flush interface between the shield and composite component without requiring separate machining or dressing operations
Solution Approach 2:
The patent utilizes the resin's flow characteristics and curing process to achieve the flush interface. By controlling resin injection parameters and curing conditions, the resin naturally conforms to the shield surface, creating a smooth transition without requiring additional mechanical finishing operations
3Object-affected harmful factors
If a thermoplastic polymer coating is applied to protect from erosion, then erosion resistance is improved, but the manufacturing process becomes more complex
Solution Approach 1:
The thermoplastic polymer coating application is merged with the composite manufacturing process. The coating is applied to the composite preform before resin injection, and both the coating and composite structure are cured together in a single autoclave cycle, eliminating the need for separate coating application and curing steps
Solution Approach 2:
The thermoplastic polymer coating is pre-applied to the composite preform before the resin injection process. This preliminary coating application allows the erosion protective layer to be integrated into the manufacturing flow, reducing the number of discrete manufacturing steps while maintaining erosion resistance
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
This approach simplifies the manufacturing process by eliminating the need for chamfering and manual dressing, while maintaining a smooth exterior profile for aerodynamic efficiency and enhancing the component's resistance to impact and erosion.
Implementation Method 1
pressing the shield into the thermoplastic polymer sheet so that the thermoplastic polymer sheet deforms around the end of the shield
Implementation Method 2
The thermoplastic polymer sheet may provide the unshielded region with improved erosion resistance
Implementation Method 3
The shield may provide the shielded region of the component with improved impact resistance
Data Source
Figure 1
Figure 2~3
Figure 4~5
AI summary
A method of manufacturing a component (32) for a gas turbine engine (10) comprises: applying a thermoplastic polymer sheet (43) over a composite body (37) for the component (32); applying a shield (35) over part of the composite body (37), the shield (35) terminating at an end (39) which overlies the thermoplastic polymer sheet (43) and defines an interface (41) between shielded and unshielded regions of the component; and pressing the shield (35) into the thermoplastic polymer sheet (43) so that the thermoplastic polymer sheet (43) deforms around the end of the shield (35), such that the exterior profile of the component at the interface (41) between the shielded and unshielded regions is flush.