Fire Protection Layer for 3D Woven Composite Gas Turbine Parts
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Solution Overview
Problem
Current fire-resistant solutions for composite material parts in gas turbine engines, such as fan casings, do not inherently self-extinguish and require bulky insulation, which is impractical for gas turbine engines, and existing methods for adding fire protection to composite parts during machining are ineffective.
Innovation Solution
A method involving preforming prepreg panels with a secondary fiber reinforcement and matrix, applying them to the part, and heat-treating to create a protective layer that self-extinguishes without degrading mechanical properties, using resins like epoxy or phenolic that maintain structural integrity and create an insulating air gap.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If fire-resistant protection is added to composite material parts, then fire resistance is improved, but the part becomes bulky and impractical for gas turbine engines
Solution Approach 1:
The patent applies a thin fire-resistant coating layer on the composite material part surface. This coating acts as a flexible protective shell that provides fire resistance without adding significant volume, thus resolving the contradiction between fire protection and compact dimensions required for gas turbine engine components.
Solution Approach 2:
The patent modifies the surface parameters of the composite part by applying a fire-resistant coating with specific thermal and chemical properties. This changes the surface characteristics to achieve fire resistance while maintaining the overall part dimensions, resolving the contradiction between fire protection and volume constraints.
2Reliability
If fire-resistant coating is applied during machining, then fire protection is improved, but the coating is eliminated in zones where several millimeters are cut off
Solution Approach 1:
The patent applies the fire-resistant coating after the final machining operations are completed. This preliminary action ensures that the coating is applied to the final part geometry, avoiding any subsequent removal during machining. The coating integrity is thus preserved in all zones, including flange areas, while maintaining fire protection effectiveness.
3Object-affected harmful factors
If self-extinguishing protection is implemented, then fire safety is improved, but the solution becomes bulky and not feasible for gas turbine engines
Solution Approach 1:
The patent employs a thin self-extinguishing coating layer that forms a flexible protective shell on the composite part surface. This coating achieves self-extinguishing properties through its chemical composition and thermal characteristics, providing fire safety without the bulky insulation required by conventional methods, thus making it feasible for gas turbine engine applications.
Solution Approach 2:
The patent uses composite coating materials with specific fire-retardant properties that enable self-extinguishing behavior. These composite materials combine multiple components to achieve both the self-extinguishing function and thin profile, resolving the contradiction between fire safety and volume constraints for gas turbine engine 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
The method effectively self-extinguishes the composite material parts while maintaining mechanical resistance and is industrially viable, reducing the extent of flame degradation and heat transfer, thus protecting the engine components from fire damage.
Implementation Method 1
fastening of the prepreg panel onto the surface by heat treatment of the part fitted with said prepreg panel to produce a protective layer against fire
Implementation Method 2
create an insulating air gap
Data Source
AI summary
The invention relates to a method for fire protection (S) of a part (1) of a gas-turbine engine made of a composite material comprising a main fibrous reinforcement compregnated by a main matrix, the protection method (S) comprising the following steps: preforming (S1) a panel of prepreg (20) such as to grant same a shape corresponding to the shape of a surface (3) of the part (1) to be protected against fire, said panel of prepreg (20) comprising a secondary fibrous reinforcement compregnated by a secondary matrix; applying (S2) the panel of prepreg (20) thus preformed to the part (1); and securing (S3) the panel of prepreg (20) to the surface (3) by thermal treatment of the part (1) provided with said panel of prepreg (20) in order to obtain a fire-protection layer (2).