Composite Turbine Blade Platform Integration via 3D Weaving
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Solution Overview
Problem
Turbine engine blades and vanes made of composite materials face issues with mechanical strength at the root and aerodynamic sealing functions, as existing methods fail to integrate both inner and outer platforms effectively, leading to potential breakage under centrifugal forces and inadequate sealing.
Innovation Solution
A method involving three-dimensional weaving of fiber blanks to create single-piece composite material blades and vanes with distinct portions for airfoils, inner platforms, and outer platforms, where yarn layers are not interlinked to maintain mechanical strength and allow for shaping without cutting, enabling both sealing and aerodynamic functions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a single-piece fiber preform is shaped to include both inner and outer platforms with integrated functions, then the blade can provide both sealing and aerodynamic functions, but the mechanical strength at the root deteriorates due to high centrifugal forces causing breakage
Solution Approach 1:
The fiber preform is divided into distinct portions: a first portion for the airfoil, a second portion for the inner platform, and a third portion for the outer platform. These portions are assembled together to form the complete blade structure, allowing each segment to be optimized for its specific function while maintaining overall structural integrity under centrifugal forces.
Solution Approach 2:
The blade is constructed using composite materials with fiber reinforcement densified by a matrix. This composite structure provides both the mechanical strength required to withstand centrifugal forces and the functional versatility to integrate sealing and aerodynamic features in the platform portions.
2Adaptability or versatility
If the fiber blank is shaped to create integrated platforms, then both sealing and aerodynamic functions can be provided, but the manufacturing complexity increases due to the need for precise shaping without cutting
Solution Approach 1:
The fiber blank is pre-shaped into a single-piece preform that includes all necessary portions (airfoil, inner platform, outer platform) before densification. This preliminary shaping establishes the complete geometric configuration in advance, avoiding the need for complex cutting operations after the blade is manufactured and ensuring proper fiber alignment for structural integrity.
Solution Approach 2:
The shaping process combines the formation of multiple functional portions (airfoil, inner platform, outer platform) into a single integrated preform manufacturing step. This merging of operations reduces the number of separate manufacturing steps and simplifies the overall production process while achieving functional integration.
Data Source
AI summary
A method for fabricating turbine engine blade or vane made of composite material includes: performing three-dimensional weaving to make a single-piece fiber blank; shaping the fiber blank to obtain a single-piece fiber preform having a first portion forming a preform for at least a blade/vane airfoil, at least one second portion forming a preform for an inner part of a blade/vane inner platform or for an outer part of a blade/vane outer platform, and at least one third portion forming a preform for an outer part of a blade/vane inner platform or for an inner part of a blade/vane outer platform; and densifying the fiber preform with a matrix to obtain a composite material blade, and forming a single piece with an inner and/or outer platform(s) incorporated therein.