Hybrid Composite Containment Cases for Gas Turbine Blades
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Solution Overview
Problem
Conventional gas turbine engine containment systems, particularly for larger diameter engines, face challenges in achieving adequate blade containment while minimizing weight and cost, as all-metallic or all-composite solutions are either too heavy or costly.
Innovation Solution
Integration of a metallic segment with a composite segment to form a hybrid composite component, where the metallic shell interlocks with composite shells to create a lightweight and cost-effective containment system.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a metallic case thick enough to resist penetration is used, then blade containment capability is improved, but weight increases prohibitively for larger diameter engines
Solution Approach 1:
The patent applies composite materials by combining metallic and composite segments into a hybrid containment case. The composite segments (made from materials like carbon fiber reinforced plastic) provide high strength-to-weight ratio, while metallic segments provide ductility and energy absorption. This composite structure achieves adequate blade containment capability without the prohibitive weight of a fully metallic thick case, directly resolving the contradiction between strength and weight for larger diameter engines.
Solution Approach 2:
The containment case is divided into multiple segments including metallic segments and composite segments arranged in an alternating pattern around the circumference. This segmentation allows each material type to contribute its specific advantages - metallic segments for ductility and composite segments for lightweight strength - while distributing the load effectively. The segmented hybrid structure achieves the required containment capability with reduced weight compared to a solid metallic case.
2Strength
If separate layers of metal and composite materials are used, then containment capability is improved, but cost increases
Solution Approach 1:
The patent merges metallic and composite materials into an integrated hybrid structure where the segments are mechanically connected through interlocking features, joints, or bonding. This unified hybrid design achieves containment capability while streamlining the manufacturing process compared to traditional separate-layer approaches. The integrated structure reduces assembly complexity and manufacturing cost while maintaining the performance benefits of combining metal and composite materials.
3Weight of stationary object
If an all-composite containment system is used, then weight is reduced, but cost increases significantly
Solution Approach 1:
The patent applies local quality by strategically placing metallic segments at specific locations within the containment case structure rather than using uniform material throughout. The metallic segments are positioned to provide ductility and energy absorption where needed, while composite segments provide lightweight strength in other areas. This localized material distribution achieves weight reduction compared to all-metallic designs while controlling costs through optimized material placement rather than expensive all-composite construction.
Data Source
AI summary
Hybrid composite components, such as gas turbine engine containment assemblies, a hybrid composite component having an annular composite shell and an annular metallic shell joined with the composite shell. A containment assembly including a containment case extending along an axial direction about a longitudinal centerline of the gas turbine engine. The containment case has an inner surface and an outer surface spaced apart along a radial direction and includes a first composite shell joined with a metallic shell. The metallic shell defining a first portion of the inner surface and the first composite shell defining a second portion of the inner surface.