Embedded 3D Structural Elements in Oxide-oxide CMC Components
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Solution Overview
Problem
Designing thin-walled oxide-oxide ceramic matrix composite (CMC) components for gas turbine engines that maintain stiffness and prevent fatigue failure while minimizing weight, as increasing the number of plies can lead to undesirable weight gain.
Innovation Solution
A method involving the layering of 2D and 3D oxide-oxide composite plies on a mandrel, with 2D woven or nonwoven oxide fibers in a first oxide matrix and 3D woven oxide fibers in a second oxide matrix, embedded within a composite body, where the matrices and fibers can comprise the same or different oxides, and sintered at high temperatures to form a reinforced component with embedded structural elements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the number of plies is increased to maintain stiffness and prevent fatigue failure, then the structural integrity is improved, but the weight increases undesirably
Solution Approach 1:
The patent employs a composite structure combining 2D oxide-oxide composite plies with embedded 3D oxide-oxide composite structural elements. The 3D woven fibers provide enhanced stiffness and fatigue resistance in critical regions, allowing the overall component to achieve required mechanical properties with fewer plies, thereby reducing weight compared to conventional uniform 2D ply structures
Solution Approach 2:
The patent applies local reinforcement by embedding 3D oxide-oxide composite structural elements at specific predetermined locations within the composite body where enhanced mechanical properties are needed. This localized approach to strengthening critical areas allows reduction of the overall number of plies while maintaining necessary stiffness and fatigue resistance, thus reducing weight
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 method achieves a significant weight advantage over superalloy components while maintaining stiffness and fatigue life, with the embedded structural elements enhancing thermomechanical properties and reducing the need for multiple plies, thus preventing weight increase.
Implementation Method 1
heating the composite preform to a temperature sufficient to sinter the first and second oxide matrix precursors
Data Source
AI summary
A reinforced oxide-oxide CMC component for a gas turbine engine includes a composite body and a structural element embedded in the composite body, where the composite body comprises a 2D oxide-oxide composite and the structural element comprises a 3D oxide-oxide composite. The 2D oxide-oxide composite includes 2D woven or nonwoven oxide fibers in a first oxide matrix, and the 3D oxide-oxide composite includes 3D woven oxide fibers in a second oxide matrix. The first oxide matrix and the second oxide matrix may comprise the same or a different oxide.