Composite Turbine Sector Manufacturing via 3D Weaving
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Solution Overview
Problem
The challenge in manufacturing turbine and compressor sectors for turbomachines is the complexity of producing composite materials that can maintain structural integrity and gas flow delimitation at high temperatures, while also simplifying the production process and ensuring secure attachment without excessive force on connections.
Innovation Solution
A method involving the production of unitary single-blade vanes with integrated inner and outer platforms, using three-dimensional weaving to create fibrous preforms, partial densification, and co-densification of the matrix to form multi-blade sectors, allowing for assembly and connection of blades with hooking lugs for secure attachment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If traditional metal sectors are used for turbine nozzles and compressor stators, then structural integrity and gas flow delimitation are achieved, but density is high and thermal management is difficult
Solution Approach 1:
The patent applies ceramic matrix composite (CMC) materials to manufacture turbine nozzle sectors and compressor stator sectors. CMC materials combine ceramic fibers with a matrix material to create a composite structure that maintains structural integrity at high temperatures while having lower density than traditional metals, thus resolving the contradiction between operating temperature and weight/density
Solution Approach 2:
The patent changes the material parameters by transitioning from metallic materials to CMC materials, fundamentally altering the density and thermal properties of the sectors. This parameter change enables the sectors to operate at higher temperatures with reduced weight while maintaining mechanical strength
2Weight of moving object
If CMC materials are used for turbine nozzle sectors, then density is reduced and high temperature resistance is improved, but manufacturing complexity increases
Solution Approach 1:
The patent segments the turbine nozzle into multiple identical sectors (typically 5-10 sectors forming a complete circle). Each sector is manufactured separately using CMC materials and then assembled into the complete nozzle. This segmentation reduces the manufacturing complexity of individual sectors while maintaining the overall performance benefits of CMC materials
Solution Approach 2:
The patent employs preliminary actions in the manufacturing process by first creating fibrous preforms through three-dimensional weaving, then shaping these preforms before final densification. This preliminary structuring of the fiber architecture simplifies the subsequent manufacturing steps and enables complex geometries to be achieved more easily
3Adaptability or versatility
If sectors are assembled from multiple blades, then structural flexibility is improved, but connection complexity and force distribution issues arise
Solution Approach 1:
The patent merges multiple blade sectors into a complete turbine nozzle or compressor stator assembly. Each sector is designed with integration features that allow seamless connection to adjacent sectors, creating a unified structure that maintains gas flow continuity while allowing for modular assembly and disassembly
Solution Approach 2:
The patent designs universal connection mechanisms that serve multiple functions: mechanical joining of sectors, sealing of gas flow paths, and distribution of thermal and mechanical loads. These multi-functional connections reduce overall complexity by eliminating the need for separate components for each function
4Reliability
If hooking lugs are used for sector attachment, then mounting security is improved, but connection forces may become excessive
Solution Approach 1:
The patent applies local quality by designing hooking lugs with specific geometric features and material properties at the connection points. The CMC material structure is locally optimized at the lug regions to distribute connection forces evenly, preventing stress concentrations that would lead to excessive forces while maintaining secure mounting
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 method simplifies the production of fiber preforms, reduces complexity in molding, and enables secure attachment of turbine and compressor sectors in composite materials, maintaining structural integrity and gas flow delimitation at high temperatures without inducing excessive forces on connections.
Implementation Method 1
producing by three-dimensional weaving a fibrous preform in one piece
Implementation Method 2
the partial densification of the preform by a matrix to obtain a blade made of composite material
Implementation Method 3
The assembly and connection of several blades together to form a multi-blade sector comprises at least one step of connection by co-densification by a matrix
Implementation Method 4
these materials have remarkable thermostructural properties, that is to say mechanical properties which make them suitable for constituting structural elements and the ability to retain these properties at high temperatures
Data Source
Figure 1
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Figure 4
AI summary
The invention relates to single-blade vanes, each of which has an inner platform (114), an outer platform (116), and a blade (118), and which are obtained by means of the three-dimensional weaving of an integral fibrous blank, shaping the fibrous blank so as to obtain an integral fibrous preform, and densifying the preform with a matrix so as to obtain a vane made of a composite material forming an integral part with inner and outer platforms. A plurality of vanes are assembled and linked together so as to form a multi-blade sector of a turbine nozzle or compressor stator vane, the linkage being carried out by means of a process including a step of linking by brazing and/or a step of linking by co-densification with a matrix of vanes assembled during an intermediate densification stage.