Composite Vane Metal Core Fastener Integration

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Solution Overview

Problem

Composite vanes for gas turbine engines face challenges in achieving a balance between lightweight design and mechanical strength, particularly in areas subjected to aerodynamic forces, and require reliable fastening solutions.

Innovation Solution

A composite vane design featuring a metal reinforcement that forms both the longitudinal core and fastener bases, integrated with an organic matrix to provide structural stiffness and aerodynamic shape, while simplifying manufacturing through direct integration of the leading edge and optimized retention points.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Weight of moving object

If a composite vane is made with metal core and organic matrix to reduce weight, then the weight decreases, but the mechanical strength and robustness deteriorate

Engineering Contradiction:

Improvevane weightVSAvoidmechanical strength

Core Design Contradiction:

Weight of moving objectVSStrength

Solution Approach 1:

The patent employs a composite structure combining metal reinforcement (providing strength and stiffness) with organic matrix material (reducing weight). The metal reinforcement forms a longitudinal core extending between fastener bases, creating a hybrid composite vane that achieves both weight reduction and maintained mechanical strength through the synergistic combination of materials with different properties.

Inventive Principle:

Principle #40Composite materials

2Strength

If metal reinforcement is used to provide structural stiffness and strength, then the mechanical strength improves, but the weight increases

Engineering Contradiction:

Improvestructural strengthVSAvoidvane weight

Core Design Contradiction:

StrengthVSWeight of moving object

Solution Approach 1:

The metal reinforcement is strategically positioned only where structurally necessary - forming a longitudinal core between fastener bases and at the leading edge - rather than throughout the entire vane. The organic matrix material fills the remaining volume, creating a non-uniform composite structure with local metal reinforcement that provides strength where needed while minimizing overall weight.

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The patent optimizes the volume fraction, distribution, and geometry of the metal reinforcement phase within the composite structure. By controlling the amount and configuration of metal material (as opposed to using solid metal throughout), the design achieves the required structural parameters for stiffness and strength while maintaining reduced weight through the lower-density organic matrix in non-critical areas.

Inventive Principle:

Principle #35Parameter changes

3Manufacturing precision

If the leading edge is made separately by fitting sheet metal, then the manufacturing precision may be maintained, but the device complexity and manufacturing time increase

Engineering Contradiction:

Improveleading edge precisionVSAvoidmanufacturing complexity

Core Design Contradiction:

Manufacturing precisionVSDevice complexity

Solution Approach 1:

The metal reinforcement is designed as an integrated single component that simultaneously forms the longitudinal core extending between fastener bases and the leading edge protective portion. This merging of functions into one piece eliminates the need for separate sheet metal fitting operations, reducing manufacturing complexity and assembly steps while maintaining precision through the integral construction.

Inventive Principle:

Principle #5Merging (Combining)

4Productivity

If the metal reinforcement forms both the longitudinal core and fastener bases as one piece, then the manufacturing efficiency improves, but the structural complexity increases

Engineering Contradiction:

Improvemanufacturing efficiencyVSAvoidstructural complexity

Core Design Contradiction:

ProductivityVSDevice complexity

Solution Approach 1:

The metal reinforcement serves multiple functions simultaneously: it provides the longitudinal core for structural stiffness, forms the leading edge protective portion, and creates the fastener bases for mounting. This multi-functional design consolidates several structural elements into one component, improving manufacturing efficiency by reducing part count and assembly operations while the structural complexity is managed through the optimized geometry of the integrated form.

Inventive Principle:

Principle #6Universality (Multi-functionality)

Data Source

PatentUS11021964B2Composite vane with metal reinforcement, and its method of manufacture

Publication Date: 2021.06.01 SAFRAN AIRCRAFT ENGINES SAS

AI summary

A composite vane includes both a vane body extending in a longitudinal direction between an inner end and an outer end and also at least one fastener base connected to the inner end or to the outer end of the vane body. The vane includes metal reinforcement associated with an organic matrix. The metal reinforcement defines integrally as a single part both a longitudinal core extending between the inner and outer ends of the vane body and also the fastener base, the longitudinal core having the organic matrix overmolded thereon, the organic matrix defining the outside shape of the vane.