Gas Turbine Fan Case Composite Ballistic Liner Design
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Gas turbine engine fan cases face challenges in balancing blade containment with the need for low weight and high strength, particularly in preventing fan blade fragments from exiting the engine while maintaining structural integrity.
Innovation Solution
A composite fan case structure utilizing unidirectional roving fiber layers and non-crimp fabric layers, combined with a fiberglass layer and an inner ballistic liner, provides a lightweight and efficient containment system, with the ballistic liner resisting ballistic threats and the composite structure replacing traditional metal alloys.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a traditional metal alloy fan case is used to contain fan blade fragments, then blade containment capability is improved, but weight increases and strength-to-weight ratio deteriorates
Solution Approach 1:
The fan case employs a composite structure consisting of a metal alloy outer case and a composite ballistic liner. The ballistic liner is constructed from multiple layers including unidirectional roving fiber layers, non-crimp fabric layers, and a fiberglass layer, combined with an inner ballistic liner. This composite material system provides superior blade containment capability while reducing overall weight compared to traditional solid metal alloy cases.
Solution Approach 2:
The ballistic liner is nested within the metal alloy outer case, creating a multi-layered containment system. The unidirectional roving fiber layers, non-crimp fabric layers, fiberglass layer, and inner ballistic liner are arranged in concentric layers, with each layer providing specific functional properties for blade fragment containment while optimizing the weight-strength relationship.
2Strength
If the fan case structure is strengthened to prevent blade fragments from exiting, then blade containment is improved, but structural weight increases
Solution Approach 1:
The composite ballistic liner provides high containment strength through the synergistic combination of unidirectional roving fibers (providing tensile strength), non-crimp fabric layers (providing multidirectional reinforcement), fiberglass layer (providing structural integrity), and inner ballistic liner (providing impact resistance). This composite system achieves superior strength-to-weight ratio compared to traditional metal alloy structures.
Solution Approach 2:
The ballistic liner is strategically positioned in the region where blade fragment impact is most likely to occur, providing localized high-strength containment exactly where needed. The multi-layer composite structure concentrates reinforcement in the critical containment zone rather than uniformly strengthening the entire fan case, thereby optimizing strength distribution and minimizing unnecessary weight.
Data Source
Figure 1
Figure 2
Figure 3~5
AI summary
A case for a gas turbine engine includes a containment section with a plurality of unidirectional roving fiber layers and a plurality of non-crimp fabric layers. A method of manufacturing the case includes winding the plurality of unidirectional roving fiber layers around the plurality of non-crimp fabric layers.