Fusible Mandrel for Composite Cooling Cavities

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Solution Overview

Problem

Existing composite components in gas turbine engines face challenges in forming intricate cooling cavities, particularly in high-temperature materials like ceramic matrix composites (CMCs) and polymer matrix composites (PMCs), which are prone to reduced thermal conductivity and complex geometry difficulties.

Innovation Solution

The use of a fugitive/fusible, two-material mandrel assembly with an inner structural body made of a metal alloy and an outer release layer of silicone, allowing for the formation of cavities within composite components during the manufacturing process.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If traditional composite manufacturing methods are used, then manufacturing simplicity is maintained, but the ability to form intricate cooling cavities is insufficient

Engineering Contradiction:

Improvecavity formation precisionVSAvoidmandrel assembly complexity

Core Design Contradiction:

Manufacturing precisionVSDevice complexity

Solution Approach 1:

The mandrel assembly is divided into two distinct materials: an inner structural body made of metal alloy and an outer release layer made of silicone. This segmentation allows each layer to perform its specific function - the metal alloy provides structural support for cavity formation while the silicone layer enables easy release, thereby achieving precise cavity formation without excessive overall complexity

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The outer release layer acts as an intermediary between the inner structural body and the composite material. This intermediary layer facilitates the removal of the mandrel assembly after curing by providing a release surface, allowing the inner structural body to maintain its precise cavity-forming function without being directly exposed to the composite material

Inventive Principle:

Principle #24Intermediary (Mediator)

2Temperature

If high-temperature materials like CMCs and PMCs are used, then high-temperature capabilities are improved, but thermal conductivity is reduced

Engineering Contradiction:

Improvehigh-temperature capabilityVSAvoidthermal conductivity

Core Design Contradiction:

TemperatureVSLoss of energy

Solution Approach 1:

The mandrel assembly uses different materials with different thermal properties in different locations. The inner structural body made of metal alloy has high thermal conductivity to facilitate heat transfer during processing, while the outer release layer made of silicone provides thermal insulation and release properties. This local differentiation allows the composite component to achieve high-temperature capability without compromising the thermal management during manufacturing

Inventive Principle:

Principle #3Local quality

3Reliability

If complex cooling cavity geometries are formed, then cooling effectiveness is improved, but manufacturing difficulty increases

Engineering Contradiction:

Improvecooling effectivenessVSAvoidcavity formation ease

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The mandrel assembly is pre-formed with the exact complex cavity geometry required before the composite material is applied. This preliminary action allows intricate cooling cavity shapes to be created without requiring complex post-processing or difficult manufacturing steps, as the geometry is established in advance by the mandrel structure itself

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The mandrel assembly, particularly the outer release layer, is designed as a temporary, disposable component that is removed after serving its purpose. This allows complex cavity geometries to be formed using a relatively simple, low-cost mandrel structure that does not need to be reused or maintained, thereby reducing manufacturing difficulty for complex shapes

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

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 enables the precise formation of cooling cavities in composite components, ensuring effective cooling while maintaining the high-temperature capabilities of CMCs and PMCs, thus enhancing the performance and efficiency of gas turbine engine components.

Implementation Method 1

removing the mandrel assembly from the composite ply core to form the cavity, wherein removing the mandrel assembly from the composite ply core comprises melting out the inner structural body

Methodology Applied

Scientific EffectMelting: Melting

Data Source

PatentUS20250114970A1Method of forming composite components with cavities

Publication Date: 2025.04.10 GENERAL ELECTRIC CO

AI summary

A method of forming a composite component includes laying up a plurality of composite plies around a mandrel assembly to form a composite ply core. The mandrel assembly includes a mandrel having an inner structural body and an outer release layer. The mandrel is configured to form a cavity in the composite ply core. The method also includes processing the composite ply core containing the mandrel assembly to compact the plurality of composite plies together. Further, the method includes removing the mandrel assembly from the composite ply core to form the cavity. Further, removing the mandrel assembly from the composite ply core includes melting out the inner structural body and removing the outer release layer after melting out the inner structural body.