Composite Turbine Blade 3D Weaving Platform Strength
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Solution Overview
Problem
Turbomachine blades made of composite material with integrated platforms and heels face issues with mechanical strength and functionality, as the existing manufacturing processes struggle to provide both sealing and aerodynamic functions effectively, and the heel spoilers can break under centrifugal forces.
Innovation Solution
A method involving three-dimensional weaving to produce a fibrous blank with separate parts for the blade root, platform, and heel spoilers, which are then densified by a matrix to form a single-piece blade with enhanced mechanical strength and functional properties, including a double-thickness platform for increased strength and reconstituted gas flow paths.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a single fibrous preform is used for blade, platform, and heel, then manufacturing complexity is reduced, but the heel cannot integrate both sealing function and aerodynamic function
Solution Approach 1:
The fibrous blank is divided into three distinct sets of layers: first set for blade and root, second set for platform, and third set for heel spoilers and reinforcement. This segmentation allows each region to be optimized independently for its specific function while maintaining overall structural integrity.
Solution Approach 2:
Different regions of the blade are assigned different fiber layer configurations tailored to local requirements. The heel region receives additional reinforcement layers and covering spoilers to provide both sealing and aerodynamic functions, while the blade region maintains its standard configuration.
2Productivity
If a single fibrous preform is used for blade, platform, and heel, then production efficiency is improved, but the platform mechanical strength is insufficient
Solution Approach 1:
The platform region is provided with a second set of fiber layers that are linked together locally to form a reinforced platform structure. This additional layering is achieved through selective bonding of fibers in the platform zone while leaving other regions unbonded.
Solution Approach 2:
The blade is constructed as a composite structure with multiple fiber sets oriented in different directions and configurations. The combination of first set (blade structure), second set (platform reinforcement), and third set (heel reinforcement) creates a multi-functional composite material system.
3Strength
If fiber layers are bonded together during shaping, then structural integrity is improved, but the ability to reconstitute gas flow paths is reduced
Solution Approach 1:
The fiber blank is designed with unbinding zones between different functional regions. The first set of layers remains unbound to the second and third sets, allowing independent deformation and reconstitution of gas flow paths in the platform and heel regions while maintaining blade structural integrity.
Solution Approach 2:
The fiber structure is designed to be dynamically adaptable during operation. The unbound fiber layers can deform independently to reconstitute gas flow paths, while the bound regions maintain structural stability. This dynamic behavior allows the blade to adapt to operational conditions.
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
The solution enables turbomachine blades with improved mechanical strength, sealing, and aerodynamic functions, ensuring the heel and platform can withstand operational forces and maintain gas flow path integrity.
Implementation Method 1
densification of the fibrous preform by a matrix to obtain a blade of composite material having a fibrous reinforcement constituted by the preform and densified by the matrix
Data Source
Figure 1
Figure 2~5
Figure 6A~6B
AI summary
A composite material turbine engine blade, including a fibrous reinforcement made denser by a matrix, is manufactured by a method that includes: creating an integral fibrous blank (100) by means of three-dimensional weaving; shaping the fibrous blank so as to obtain an integral fibrous preform that has a first portion (102) forming a preform of the blade vane and foot, at least one second portion (104) forming a blade platform preform or blade root member preform, and at least one third portion (106) forming a blade platform preform or blade root covering spoiler preform; and making the fibrous preform denser by means of a matrix so as to obtain a composite material blade that has a fibrous reinforcement, consisting of the preform and made denser by the matrix, said blade forming a single part with a built-in platform and/or root.