Turbine Fan Casing Acoustic Coating Integration
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Solution Overview
Problem
The existing methods for manufacturing turbine engine fan casings using fiber-matrix composite materials face issues with mechanical property degradation due to repeated drilling for acoustic panel fastening and residual deformation, which affects the air inlet passage profile.
Innovation Solution
A method involving the use of a tooling element to deposit and shape fiber reinforcement with integrated acoustic and abradable coatings, followed by polymerization and perforation to create a seamless assembly that maintains the air inlet passage profile without deformation, using a common resin for both the casing and acoustic coating.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If acoustic panels are fastened to the casing by drilling and screwing, then the acoustic treatment can be installed, but the mechanical properties of the composite material are degraded
Solution Approach 1:
The acoustic coating is integrated directly into the fiber preform structure before casing formation, merging the acoustic treatment function with the structural casing. This eliminates the need for separate fastening operations (drilling and screwing) that would degrade the composite material's mechanical properties.
Solution Approach 2:
The acoustic coating is applied and integrated into the fiber preform during the preliminary manufacturing stage, before the casing is completed and installed. This preliminary integration avoids subsequent drilling and fastening operations that would compromise the mechanical integrity of the composite material.
2Object-affected harmful factors
If acoustic panels are fastened using adhesive, then the panels can be attached without drilling, but residual deformation occurs degrading the air inlet passage profile
Solution Approach 1:
The acoustic coating is merged with the fiber preform structure during manufacturing, creating an integrated component that forms the air inlet passage profile together with the casing. This eliminates the need for adhesive bonding that would cause residual deformation and profile degradation.
Solution Approach 2:
The acoustic coating is transformed from a separate attachable panel into an integrated part of the composite structure through chemical bonding with the resin matrix during polymerization. This parameter change in integration method eliminates adhesive-induced deformation while maintaining profile precision.
3Reliability
If a large number of inserts and screws are used to fasten acoustic panels, then the acoustic treatment can be securely attached, but the device complexity increases
Solution Approach 1:
The acoustic coating is combined with the fiber preform into a single integrated structure, eliminating the need for multiple separate components (inserts, screws, panels). This merging maintains attachment security through structural integration while dramatically reducing device complexity.
Solution Approach 2:
The fiber preform serves multiple functions simultaneously: it provides the structural framework of the casing, incorporates the acoustic treatment function through integrated cellular structures, and defines the air inlet passage geometry. This multi-functionality eliminates the need for separate acoustic panel components.
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
This method avoids mechanical property degradation and profile irregularities, ensuring accurate air inlet passage definition and efficient integration of acoustic and abradable coatings within the composite material casing.
Implementation Method 1
subjecting both the fiber preform of the casing as held in its shape and impregnated with a precursor resin for the matrix of the composite material of the casing and also the fiber structure of the inside skin of the acoustic coating as impregnated with a precursor resin for the matrix of the composite material of said inside skin to common polymerizing resin heat treatment
Implementation Method 2
supports a soundwave absorber structure for acoustic treatment at the inlet of the engine
Data Source
AI summary
A method for manufacturing a turbine engine fan casing includes placing a fiber structure constituting the fiber reinforcement of a composite material inside skin of an acoustic coating on a tooling element, and then shaping the fiber preform constituting the fiber reinforcement of an abradable casing on the tooling element with cellular structures of acoustic coating and abradable coating cartridges, if any, being interposed. Both the fiber preform of the casing as impregnated by a precursor resin for the matrix of the composite material of the casing, and also the fiber structure of the inside skin of the acoustic coating as impregnated with a precursor resin for the matrix of the composite material of the inside skin are subjected to resin polymerizing heat treatment, and the inside skin of the acoustic coating is multiply perforated so an assembly is obtained that comprises the casing with an incorporated acoustic coating.