Composite Turbine Vane Platform Fabrication via Fiber Blank Folding
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Solution Overview
Problem
Turbine engine vanes made of composite materials with integrated platforms face challenges in mechanical strength, particularly in traction strength due to deformation and detachment of filler elements at platform-airfoil junctions, leading to increased fabrication complexity and costs.
Innovation Solution
A method involving multilayer weaving to create a fiber blank with non-interlinking zones, where segments are folded to form platforms and filled with fiber texture from the blank, eliminating the need for separate fillers, and densified with a matrix to enhance both compression and traction strength.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a filler element is added to fill the groove between platform portions, then compression strength is improved, but fabrication complexity increases and traction strength remains problematic
Solution Approach 1:
The invention extracts the filler element from being a separate component and transforms it into an integrated part of the fiber blank structure. The groove-filling function is achieved through the natural folding and positioning of the first portion during preform formation, eliminating the need for separate filler insertion operations.
Solution Approach 2:
The invention merges the groove-filling function with the platform portions by designing the fiber blank to include a first portion that naturally fills the groove when folded. This integration eliminates separate filler elements and combines multiple functions (platform formation and groove filling) into a single continuous fiber structure.
2Strength
If a filler element is added to fill the groove between platform portions, then compression strength is improved, but the number of fabrication operations increases
Solution Approach 1:
The fiber blank structure is designed to be self-filling during the folding process. The first portion automatically positions itself into the groove between the second and third portions when folded, eliminating the need for separate filler insertion operations and reducing fabrication steps.
Solution Approach 2:
The fiber blank is pre-configured with the first portion positioned to fill the groove before the actual platform folding occurs. This preliminary arrangement ensures that the groove is already prepared to receive the filling material during the natural folding process, eliminating subsequent filling operations.
3Strength
If filler element is used to fill the groove, then compression strength improves, but traction strength remains problematic due to deformation and detachment
Solution Approach 1:
The invention uses a composite fiber structure where the first portion is made of the same fiber material as the platform portions, ensuring compatible mechanical properties and strong bonding. This composite approach ensures that the filling material deforms and bonds similarly to the surrounding structure under traction loads.
Solution Approach 2:
The invention achieves homogeneity by using the same fiber material for the first portion (filler) and the second and third portions (platforms). This material uniformity ensures consistent mechanical behavior, bonding characteristics, and deformation patterns throughout the structure, eliminating detachment issues under traction.
Data Source
AI summary
A method of fabricating a composite material part having a body secured to at least one platform present at one end of the body, the method including using the fiber blank to form a preform for the part that is to be made by folding out segments of the second and third portions that are not interlinked with the first portion on opposite sides of the first portion, by shaping the folded-out segments of the second and third portions to form preform portions for a platform of the part to be fabricated, and by folding down the segment of the first portion in order to fill in the groove present in the gap between the second and third portions; and densifying the preform with a matrix in order to obtain a part made of composite material having at least one integrated platform.