Insulated Vane Arc Segment Mounting for CMC Thermal Stress
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Solution Overview
Problem
Gas turbine engine vane arc segments made from ceramic matrix composites face challenges due to thermal stress and thermal gradient issues, which can lead to material distress and reduced durability, especially when cooling methods exacerbate these problems.
Innovation Solution
The implementation of a thermal insulation element, such as a ceramic split ring, is placed between the airfoil piece and the metallic support hardware to prevent direct thermal conductance and reduce thermal gradients, while also reducing play between the airfoil and support hardware through precise machining based on a digital three-dimensional model of the radial flange.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If cooling methods are applied to ceramic matrix composite vane arc segments, then temperature control is improved, but thermal stress and thermal gradient issues worsen
Solution Approach 1:
A thermal barrier coating is applied as an intermediary layer between the ceramic matrix composite airfoil piece and the metallic support hardware. This coating acts as a thermal mediator that reduces heat transfer to the support structure while protecting the CMC material from thermal shocks, thereby controlling temperature without creating harmful thermal gradients
2Reliability
If play between airfoil piece and support hardware is reduced through precise machining, then aerodynamic loading consistency is improved, but manufacturing complexity worsens
Solution Approach 1:
A digital three-dimensional model of the radial flange is created to guide precise machining of the airfoil piece and support hardware mating surfaces. The digital model serves as a self-documenting reference that ensures consistent play reduction across production batches without requiring complex manual measurement and adjustment procedures
3Temperature
If thermal barrier coating is applied to extend temperature capability, then temperature resistance is improved, but manufacturing complexity worsens
Solution Approach 1:
The thermal barrier coating is applied as a preliminary protective layer during the manufacturing process, before the component enters service. This preliminary action of coating integration allows the base CMC material to be manufactured using standard processes while the coating is subsequently applied through established coating techniques, extending temperature capability without fundamentally complicating the core manufacturing workflow
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 solution effectively reduces thermal stress on ceramic matrix composite vane arc segments, enhances durability, and minimizes play to maintain consistent aerodynamic loading and flow area, thereby improving the operational reliability of the gas turbine engine.
Implementation Method 1
a thermal insulation element, such as a ceramic split ring, is placed between the airfoil piece and the metallic support hardware to prevent direct thermal conductance and reduce thermal gradients
Data Source
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AI summary
A vane arc segment (60) includes an airfoil piece (62) that defines first and second platforms (64, 66) and an airfoil section (68) that extends between the first and second platforms (64, 66). The first platform (64) defines a gaspath side (64a), a non-gaspath side (64b), and a first platform radial flange (72) that projects from the non-gaspath (64b) side. Support hardware (74) supports the airfoil piece (62) via the first platform radial flange (72). A thermal insulation element (76) is situated adjacent the first platform radial flange (72). The support hardware (74) supports the airfoil piece (62) through the thermal insulation element (76).