Composite Assembly Non-Destructive Imaging for Turbine Quality Control

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Solution Overview

Problem

The existing methods for manufacturing composite materials in turbine engines require destructive testing to ensure the composite assembly is formed as intended, leading to material waste and inefficiency.

Innovation Solution

The use of a composite assembly with a set of stacked composite plies, where at least a portion of the fiber bundles include a first subset of fibers and a second subset of fibers, allowing for non-destructive evaluation through imaging techniques like X-ray, ultrasound, or magnetic resonance imaging.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If destructive testing is used to inspect composite materials, then quality control is achieved, but material is wasted and manufacturing efficiency decreases

Engineering Contradiction:

Improvequality controlVSAvoidmanufacturing efficiency

Core Design Contradiction:

ReliabilityVSProductivity

Solution Approach 1:

The patent replaces destructive mechanical testing with non-destructive evaluation using imaging techniques. Composite assemblies include imaging features (such as radiopaque markers or acoustic reflectors) that enable visualization of fiber orientation and composite structure through X-ray, ultrasound, or other imaging methods, allowing quality verification without cutting or destroying the part.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent introduces imaging features as intermediary elements within the composite structure. These features serve as mediators that allow indirect observation of fiber orientation and composite integrity through non-destructive imaging, enabling quality control while preserving the actual composite material for continued use.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Manufacturing precision

If composite assemblies are cut apart for inspection, then formation intent is verified, but the composite assembly is destroyed

Engineering Contradiction:

Improveformation verificationVSAvoidmaterial destruction

Core Design Contradiction:

Manufacturing precisionVSLoss of substance

Solution Approach 1:

The patent replaces mechanical cutting and visual inspection with non-destructive imaging techniques. Imaging features embedded in the composite assembly allow verification of fiber orientation and formation intent through X-ray, ultrasound, or other imaging modalities without physically cutting or destroying the material.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent creates an informational copy of the composite structure's internal state through imaging. The imaging features produce a visual representation or map of fiber orientation and composite formation that can be analyzed without physically accessing or destroying the actual composite structure.

Inventive Principle:

Principle #26Copying

3Reliability

If traditional inspection methods are used, then quality is ensured, but manufacturing time and resources are consumed

Engineering Contradiction:

Improvequality assuranceVSAvoidmanufacturing time

Core Design Contradiction:

ReliabilityVSLoss of time

Solution Approach 1:

The patent incorporates imaging features during the composite manufacturing process itself, before final inspection is needed. These features are built into the structure during layup or curing, enabling immediate non-destructive verification without requiring separate destructive testing steps that would consume additional time and resources.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The patent replaces time-consuming destructive testing procedures with rapid non-destructive imaging techniques. The imaging features enable quick verification of fiber orientation and composite formation through X-ray or ultrasound, significantly reducing inspection time compared to cutting, examining, and reconstructing composite parts.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

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 enables the imaging of composite assemblies without destruction, reducing manufacturing burdens, allowing for efficient quality control, and extending the lifespan of composite components by providing a non-destructive means of monitoring their integrity over time.

Implementation Method 1

The composite assembly can be imaged through non-destructive evaluation. The composite assembly can be imaged directly after manufacture through non-destructive evaluation.

Methodology Applied

Scientific EffectX-ray imaging: X-Ray

Implementation Method 2

non-destructive evaluation through imaging techniques like X-ray, ultrasound, or magnetic resonance imaging

Methodology Applied

Scientific EffectUltrasound imaging: Ultrasound

Data Source

PatentUS12320272B2Turbine engine having a composite assembly

Publication Date: 2025.06.03 GENERAL ELECTRIC CO

AI summary

A turbine engine including a fan section, a compressor section, a combustion section, and a turbine section in serial flow arrangement. The turbine engine further having a composite assembly provided within at least one of the fan section, the compressor section, the combustion section or the turbine section. The composite assembly including a set of stacked composite plies, with each ply of the set of stacked composite plies being made from a plurality of fibers.