Gas Turbine CMC Components with Tapered Inserts for High-Temperature Integrity
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Solution Overview
Problem
Forming complex shapes in gas turbine engine components using ceramic matrix composite (CMC) plies is challenging, particularly in maintaining component integrity under high-temperature conditions.
Innovation Solution
The use of CMC fabric layers with inserts having tapered ends, formed through a compression process using molds with curved portions to create thinner ends, and the incorporation of noodles made of different materials to facilitate bending, along with the use of a binder for stabilization during the formation process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If CMC plies are used to form turbine section components, then high-temperature resistance is improved, but manufacturing complexity increases
Solution Approach 1:
The component is divided into multiple fabric layers (plies) that can be manufactured and assembled separately. Each layer can be optimized for specific functions, and the modular structure allows for easier manufacturing and quality control while maintaining high-temperature resistance throughout the component structure.
Solution Approach 2:
The patent utilizes ceramic matrix composite (CMC) materials which combine ceramic fibers in a matrix structure. This composite material provides superior high-temperature resistance compared to traditional materials, enabling the component to withstand turbine section temperatures while maintaining structural integrity.
2Adaptability or versatility
If complex shapes are formed using CMC plies, then component functionality is improved, but manufacturing precision deteriorates
Solution Approach 1:
Complex shapes are achieved by stacking and shaping multiple fabric layers, where each layer can be formed to specific geometric requirements. This segmentation allows the complex overall shape to be built from simpler, more precisely controllable individual layers.
Solution Approach 2:
The patent achieves complex three-dimensional shapes by controlling the arrangement, orientation, and compression of multiple two-dimensional fabric layers. By manipulating layers in the thickness dimension through differential compression, complex 3D geometries are formed from 2D precursor materials, improving manufacturing precision.
3Ease of manufacture
If uniform compression is applied to fabric layers, then manufacturing simplicity is improved, but shape precision deteriorates
Solution Approach 1:
The patent implements differential compression where different regions of the fabric layer assembly undergo different compression forces. This allows specific areas to be thinned or thickened according to functional requirements, achieving precise thickness control and complex geometries while maintaining a relatively simple overall compression process.
Solution Approach 2:
By introducing variation in the thickness dimension through localized compression, the patent transforms uniformly thick layers into components with precisely controlled thickness profiles. This enables complex shapes to be formed without fundamentally complicating the compression manufacturing process.
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 allows for the creation of robust CMC components with reduced thickness variations, enhancing their ability to withstand high temperatures and maintain structural integrity in turbine sections.
Implementation Method 1
bringing a second mold half onto the plurality of fabric layers to compress the fabric layers at an end associated with the at least one curved portion of the first mold half to form an insert having a thinner thickness at the at least one end than found at an intermediate portion spaced from the at least one end
Data Source
AI summary
A component includes fabric layers of ceramic matrix composite (“CMC”) fabric. The fabric has layers separated by an insert formed of the CMC fabric. The insert has at least one tapered end. The tapered end has a thickness which is less than a central thickness of the insert. A method is also disclosed.