Hybrid Blisk with Low-Density Insert for Gas Turbine
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Solution Overview
Problem
Conventional gas turbine fan rotors are either too heavy due to all-metal blades, leading to lower fuel performance, or too susceptible to damage from bird strikes due to all-composite blades, and require separate mechanical attachments which add weight and complexity.
Innovation Solution
A hybrid blisk design featuring a metallic hub with integral airfoil-shaped blades, where a less dense insert is embedded within the blade to reduce overall mass and enhance impact resistance, eliminating the need for separate mechanical attachments.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If all-metal blades are used, then strength and impact resistance are improved, but weight increases leading to lower fuel performance
Solution Approach 1:
The blade is constructed as a composite structure with a metallic body providing strength and impact resistance, and a nonmetallic insert with lower density reducing overall weight. This composite approach allows the blade to maintain structural integrity while achieving weight reduction for improved fuel performance.
2Weight of moving object
If all-composite blades are used, then weight is reduced improving fuel performance, but susceptibility to damage from bird strikes increases
Solution Approach 1:
The blade combines metallic and nonmetallic materials in a composite structure where the metallic body provides the necessary impact resistance against bird strikes while the nonmetallic insert reduces weight. This resolves the contradiction by assigning different functional requirements to different material components.
3Ease of repair
If separate mechanical attachments are used to connect blades to rotor, then ease of repair is improved, but device complexity and weight increase
Solution Approach 1:
The blade is formed as an integral part of the rotor assembly, eliminating separate mechanical attachments. The blade body extends continuously from the rotor hub, simplifying the overall structure while maintaining repairability through modular blade design that can be replaced without complex attachment mechanisms.
4Ease of manufacture
If separate mechanical attachments are used to connect blades to rotor, then ease of assembly is improved, but device complexity and weight increase
Solution Approach 1:
The blade and rotor hub are formed as a single integral structure, eliminating the need for separate attachment components. This merging of parts reduces device complexity and removes the need for complex assembly procedures while maintaining manufacturing feasibility through appropriate forming processes.
Data Source
AI summary
A rotor assembly or “blisk” for a gas turbine engine includes a metallic hub having an annular flowpath surface, and at least one blade extending outwardly from the flowpath surface. The blade includes a metallic body having a first density. The metallic body defines a shank portion and an airfoil portion having opposed pressure and suction sides, and is integral with the hub. An insert having a second density less than the first density is carried by the body, and the insert and the body collectively define an airfoil shape. A method is also provided for manufacturing a rotor assembly.