Composite Turbine Vane Fabrication with Integrated Platforms
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Solution Overview
Problem
Current methods for fabricating turbine engine vanes with inner and outer platforms are complex and lack a simplified approach for using composite materials effectively, particularly in high-temperature applications where ceramic matrix composites (CMCs) are desired for improved thermostructural properties.
Innovation Solution
A method involving multilayer weaving to form a fiber blank with specific interlinked and non-interlinked zones, which is then shaped and densified with a matrix to create a composite material vane incorporating inner and outer platforms, allowing for the formation of a hollow airfoil and platforms suitable for turbine nozzles or compressor diffusers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If conventional methods are used to fabricate turbine engine vanes with platforms, then the structural integrity and functionality are achieved, but the manufacturing complexity increases significantly
Solution Approach 1:
The blank is divided into three distinct woven portions (first, second, and third portions) with different interlinking characteristics. The first portion has yarns interlinked only over a fraction of its longitudinal dimension, creating a non-interlinked zone that enables hollow structure formation. The second and third portions are interlinked with the first portion only at longitudinal end portions, allowing independent shaping of platforms while maintaining overall structural integrity through selective interlinking.
Solution Approach 2:
The invention transitions from traditional solid vane structures to a three-dimensional woven architecture with controlled interlinking zones. By manipulating the interlinking dimension (fractional longitudinal interlinking in the first portion versus end-portion interlinking in second and third portions), the method enables simultaneous formation of hollow airfoil and solid platforms from a single integrated blank.
2Temperature
If ceramic matrix composite materials are used for high-temperature applications, then thermostructural properties are improved, but material density increases
Solution Approach 1:
The blank exhibits spatially varying interlinking density across different zones. The first portion has reduced interlinking (non-interlinked zone) suitable for hollow airfoil structure requiring lower density, while the second and third portions have full interlinking appropriate for solid platforms requiring structural strength. This local differentiation optimizes the density-strength balance in different functional regions.
Solution Approach 2:
The invention uses ceramic matrix composite (CMC) materials with fiber reinforcement arranged in a multilayer woven structure. The composite architecture provides high-temperature capability through ceramic matrix while maintaining reduced density compared to conventional metals, particularly in the hollow airfoil portion where material is strategically omitted.
3Productivity
If a single blank is used to form both airfoil and platforms, then manufacturing steps are reduced, but the shaping complexity increases
Solution Approach 1:
The blank is pre-woven with predetermined interlinking patterns before shaping operations. The fractional interlinking in the first portion and end-portion interlinking in second and third portions are established during weaving, creating built-in guides for subsequent shaping. This preliminary structural configuration enables accurate formation of hollow airfoil and solid platforms during molding without requiring complex post-processing.
Solution Approach 2:
The invention controls the interlinking parameter (extent of yarn interconnection) to create distinct zones with different mechanical properties. The non-interlinked zone in the first portion allows easy formation of hollow structures, while the interlinked zones in second and third portions maintain structural integrity during shaping. This parameter differentiation simplifies the shaping process by providing natural structural cues.
Data Source
AI summary
Multilayer weaving is used to form a fiber blank having a longitudinal direction corresponding to the longitudinal direction of the vane to be made and comprising across its thickness a first woven portion with a plurality of layers of yarns interlinked by weaving, and also a second and third woven portions. The first portion is situated between the second and third portions and interlinked thereto by weaving over only a fraction of its longitudinal dimension. A preform for the vane is formed by folding out, on either side of the first portion, segments of the second and third portions not interlinked with the first portion, by shaping the first portion to form a preform portion for the airfoil of the vane, and by shaping the folded-out segments of the second and third portions to form preform portions for the inner and outer platforms of the vane to be fabricated.