Low-Pressure Compressor Vane Leading-Edge Plating for Weight Reduction

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Solution Overview

Problem

Existing airfoils face challenges in manufacturing efficiency, weight, strength, and erosion resistance, particularly in low pressure compressor vanes, which are time-consuming and costly to bond and require robustness against foreign object impacts.

Innovation Solution

A vane design with recess areas on the leading edge featuring deposited metal on the suction and pressure sides, optimized for weight reduction, stiffness enhancement, and erosion protection, using materials like aluminum, copper, nickel, or titanium, with tailored shapes for foreign object impact resistance and frequency tuning.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If a leading edge sheath is bonded to the airfoil body, then erosion protection is improved, but manufacturing complexity and cost increase

Engineering Contradiction:

Improveerosion protectionVSAvoidmanufacturing complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent merges the leading edge sheath and airfoil body into a single integrated component, eliminating the need for separate bonding operations. The recess area is formed directly in the airfoil body, and the deposited metal is applied directly to this recess, creating a unified structure that provides erosion protection without the complexity of assembling and bonding separate components.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The patent extracts the leading edge portion of the airfoil body to create a recess area, then replaces it with deposited metal material. This extraction approach allows the protective metal layer to be precisely positioned where erosion protection is most needed, while maintaining the overall integrated structure and avoiding the need for complete sheath bonding.

Inventive Principle:

Principle #2Taking out (Extraction)

2Reliability

If metal is deposited on the leading edge recess area, then erosion resistance and strength are improved, but weight increases

Engineering Contradiction:

Improveerosion resistanceVSAvoidvane weight

Core Design Contradiction:

ReliabilityVSWeight of moving object

Solution Approach 1:

The patent applies deposited metal only to the recess area on the leading edge, specifically targeting the regions most susceptible to erosion and foreign object impact. By concentrating the heavy, erosion-resistant metal material only where needed rather than coating the entire vane surface, the design achieves maximum protection with minimum weight penalty.

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The patent uses partial action by depositing metal only on the recess area rather than the entire leading edge or full vane surface. This selective deposition provides sufficient erosion protection for the critical high-impact zones while avoiding the excessive weight that would result from complete surface coating.

Inventive Principle:

Principle #16Partial or excessive action

3Weight of moving object

If the recess area is minimized, then weight is reduced, but protection capability may be compromised

Engineering Contradiction:

Improvevane weightVSAvoidprotection capability

Core Design Contradiction:

Weight of moving objectVSReliability

Solution Approach 1:

The patent carefully designs the recess area geometry and deposited metal distribution to concentrate protection exactly where foreign object impact probability is highest. By analyzing impact patterns and placing the protective metal layer precisely in these critical zones, the design achieves adequate protection capability with minimized material usage and weight.

Inventive Principle:

Principle #3Local quality

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

The design provides lightweight, robust vanes with improved aerodynamic performance and extended service life by minimizing weight, enhancing stiffness, and protecting against foreign object impacts, suitable for gas turbine engines and other applications.

Implementation Method 1

robust airfoils capable of withstanding erosion, abrasion, and impact from foreign objects

Methodology Applied

Scientific EffectErosion resistance: Erosion

Implementation Method 2

the recess area of the vane of the gas turbine engine is shaped to increase the stiffness of the vane to tune a frequency of the gas turbine engine

Methodology Applied

Scientific EffectStiffness enhancement:

Implementation Method 3

the deposited metal on the suction side recess area has a surface roughness of less than or equal to 40 microinches (1.016 μm) for the arithmetic average roughness (Ra)

Methodology Applied

Scientific EffectSurface roughness reduction:

Data Source

PatentEP4632194A1Leading edge plating on low pressure compressor vane for weight and strength optimization

Publication Date: 2025.10.15 PRATT & WHITNEY CANADA CORP

Figure 1
Figure 2A~2C
Figure 3A~3B

AI summary

A vane (100) including an airfoil body extending from a root to a tip defining a longitudinal axis therebetween, wherein the airfoil body includes a leading edge (101) between the root and the tip. The vane (100) includes a pressure side (108) and a suction side (106) and a recess area (210) on the leading edge (110). The recess area (210) includes a pressure side recess area (107) and a suction side recess area (102), and a metal is deposited on the recess area (210). A method of manufacturing the vane (100) and a gas turbine engine including the vane (100) are also disclosed.