Geared Turbofan Core Using CMC Turbine Parts to Cut Cooling Flow
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Solution Overview
Problem
Conventional gas turbine engines face challenges in reducing fuel burn and weight, with incremental improvements over the years, and there is a need for more efficient designs that minimize cooling flow impact on efficiency and reduce overall engine mass.
Innovation Solution
Incorporating ceramic matrix composites (CMCs) in specific components of the turbine, optimizing their use to balance thermal capability and thermal conductivity, and utilizing a reduction gearbox to drive the fan at a lower speed while maintaining high rotational speeds in the second turbine shaft, along with efficient cooling and bypass flow management.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If conventional metal alloys are used in turbine components, then sufficient operating life is achieved, but turbine mass and cooling requirements increase
Solution Approach 1:
The patent applies ceramic matrix composite (CMC) materials in turbine components, specifically using CMC for the second turbine rotor blades and surrounding seal segments. This composite material approach reduces turbine mass while maintaining or improving operating life, as CMC materials offer superior temperature resistance and mechanical properties compared to conventional metal alloys, eliminating the need for extensive cooling systems.
2Reliability
If cooling flow is increased to extend component life, then operating life is improved, but engine efficiency deteriorates
Solution Approach 1:
By using CMC materials in the second turbine, the patent eliminates the need for extensive cooling flow that would otherwise be required to protect metal components from high temperatures. The CMC material inherently withstands high temperatures without melting, thereby extending component life without sacrificing engine efficiency.
3Weight of moving object
If turbine mass is reduced, then engine weight is improved, but thermal capability may deteriorate
Solution Approach 1:
The patent uses ceramic matrix composite (CMC) materials which possess both low density (reducing mass) and superior high-temperature resistance (maintaining thermal capability). The CMC material structure provides inherent temperature resistance without requiring heavy cooling systems, thus achieving mass reduction while preserving or enhancing thermal capability.
4Temperature
If CMC materials are used in turbine components, then temperature resistance is improved, but manufacturing complexity increases
Solution Approach 1:
The patent applies CMC materials selectively to specific components (second turbine rotor blades and surrounding seal segments) rather than throughout the entire turbine assembly. This localized application approach allows the design team to focus manufacturing efforts on critical high-temperature zones, thereby improving temperature resistance where needed while minimizing the overall manufacturing complexity and cost.
Data Source
AI summary
A highly efficient gas turbine engine is provided. The fan of the gas turbine engine is driven from a turbine via a gearbox, such that the fan has a lower rotational speed than the driving turbine, thereby providing efficiency gains. The efficient fan system is mated to a core that has low cooling flow requirements and/or high temperature capability, and which may have particularly low mass for a given power.