Composite Turbine Blade via 3D Weaving
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Solution Overview
Problem
Existing turbomachine blades face challenges in achieving the required mechanical properties and complex shapes, especially when incorporating inner and outer platforms, while maintaining high temperature resistance and reducing weight, which is crucial for gas turbines.
Innovation Solution
A method of fabricating turbomachine blades using three-dimensional weaving to create a one-piece fiber blank with interlaced portions for the airfoil and root, and optional inner or outer platforms, densified with a matrix to form a composite material blade, ensuring mechanical strength and complex shape integrity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If traditional metal alloys are used for turbine blades, then mechanical strength and structural integrity are ensured, but weight is increased and high-temperature resistance is reduced
Solution Approach 1:
The patent employs ceramic matrix composite (CMC) materials consisting of fiber reinforcement (such as silicon carbide or carbon fibers) embedded in a ceramic matrix. This composite structure provides both high-temperature resistance and reduced weight compared to traditional metal alloys, directly resolving the contradiction between temperature resistance and weight reduction
2Strength
If composite material blades are fabricated to reduce weight and increase temperature resistance, then mechanical properties and high-temperature performance are improved, but manufacturing complexity increases due to the need for complex shaping and fiber arrangement
Solution Approach 1:
The patent uses a preform technique where the fiber reinforcement structure is prepared in advance with the desired complex shape and internal architecture before matrix infiltration. This preliminary shaping of the fiber preform allows subsequent matrix impregnation to proceed more easily, reducing overall manufacturing complexity while maintaining mechanical properties
Solution Approach 2:
The patent implements varying fiber orientations, densities, and material compositions in different regions of the blade to optimize local mechanical properties and thermal resistance. This localized customization allows the blade to meet specific performance requirements in different zones without requiring uniformly complex manufacturing throughout the entire structure
3Object-generated harmful factors
If turbine blades are designed with incorporated inner and outer platforms to reduce polluting emissions, then environmental performance is improved, but structural integrity and mechanical strength at connection zones may be compromised
Solution Approach 1:
The patent uses CMC composite materials throughout the blade structure, including at the platform connection zones. The composite nature provides both the weight reduction for emission control and the structural integrity needed for reliable operation, as the fiber-matrix composite structure distributes stresses effectively across complex geometries
Solution Approach 2:
The patent optimizes fiber orientation, density, and material composition specifically at the platform connection zones to ensure adequate structural integrity and stress distribution. This localized reinforcement maintains reliability at critical connection points while allowing the overall blade design to achieve emission reduction goals through platform incorporation
Data Source
AI summary
A method of fabricating a turbomachine blade out of a composite material including fiber reinforcement densified by a matrix, the method including making a one-piece fiber blank by three-dimensional weaving; shaping the fiber blank to obtain a one-piece fiber preform having a first portion forming a blade airfoil and root preform and at least one second portion forming a preform for an inner or outer blade platform; and densifying the preform with a matrix to obtain a composite material blade having fiber reinforcement constituted by the preform and densified by the matrix, forming a single part with incorporated inner and/or outer platform.