Continuous Support Ring for CMC Vane Structural Integrity
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Solution Overview
Problem
Implementing ceramic matrix composite (CMC) materials in gas turbine engine airfoils is challenging due to unique structural and assembly requirements, particularly in providing robust support and efficient cooling while minimizing manufacturing complexity and potential leak paths.
Innovation Solution
A vane system with hollow airfoil fairings and spars supported by a continuous support ring with radially oriented through-holes and affixed spar flanges, using fasteners or cover plates for secure attachment, and an annular plenum for cooling air delivery, facilitating robust mechanical support and efficient cooling without inter-segment joints.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a continuous support ring is used to support multiple vane assemblies, then structural integrity and reduced leak paths are improved, but device complexity increases due to the need for precise through-hole alignment and continuous ring fabrication
Solution Approach 1:
Multiple discrete support segments are merged into a single continuous support ring structure. This integration eliminates the interfaces between segments, reducing potential leak paths and improving structural integrity while maintaining support for multiple vane assemblies through a unified design
2Temperature
If hollow airfoil fairings with spars are used for CMC vanes, then cooling efficiency is improved through internal cooling passages, but manufacturing precision requirements increase due to the complexity of forming hollow structures with integrated spars
Solution Approach 1:
The airfoil structure is segmented into distinct functional components: the hollow airfoil fairing for aerodynamic flow and cooling, the spar for structural support, and the flange for mounting. This segmentation allows each component to be manufactured and cooled independently, then assembled together, reducing the overall manufacturing precision requirements while maintaining effective cooling through the hollow passages
3Strength
If spar flanges are affixed to the continuous support ring with multiple fasteners, then mechanical strength is improved, but device complexity increases due to the number of fastening components and assembly steps
Solution Approach 1:
Multiple fastening functions are merged into a single integrated cover plate structure. The cover plate simultaneously provides radial constraint, axial positioning, and fastening attachment points, eliminating the need for multiple separate fastening components and reducing assembly complexity while maintaining the mechanical strength required for securing spar flanges to the continuous support ring
Data Source
AI summary
A vane system includes a plurality of vane assemblies and a continuous support ring. The vane assemblies are arranged circumferentially about an axis and each include a hollow airfoil fairing and a spar. The spar has a spar flange and a spar leg extending radially inwardly from the spar flange and through the hollow airfoil fairing. The continuous support ring has radially inner and outer sides and defines a circumferential row of through-holes between the radially inner and outer sides. The spar legs extend through the through-holes and the spar flanges are affixed at the radially outer side of the continuous support ring.