Integrated CMC Case Stator for Gas Turbine Engine
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Solution Overview
Problem
Traditional gas turbine engine components, such as vane attachments and gaps between vanes, lead to thermal mechanical fatigue, leakage pathways, and reduced engine efficiency due to complex machined features and gaps, which cause thermal hot-spots and inefficiencies.
Innovation Solution
An integrated case/stator segment made of ceramic matrix composite material, comprising a cylindrical case section, radially inward box structure sections, and vane airfoil sections forming a single unitary component, which minimizes gaps and enhances sealing by using CMC materials for improved thermal resistance and structural integrity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of repair
If traditional hooks and machined features are used to attach vanes, then vanes can be individually replaced, but thermal mechanical fatigue and low cycle fatigue cracking areas are created reducing reliability
Solution Approach 1:
The patent merges the vane attachment features directly into the cast structure of the turbine component, eliminating separate hooks and machined features. The integral casting process creates a unified structure where vanes are attached through built-in attachment portions, removing the need for separate fastening hardware and reducing stress concentration points that cause fatigue cracking.
2Ease of manufacture
If gaps are provided between vanes or vane clusters, then assembly is simplified, but leakage pathways are created that lower engine efficiency
Solution Approach 1:
The patent introduces an intermediary sealing structure consisting of a first seal at the forward end and a second seal at the aft end of the vane cluster. These seals act as mediators that block leakage pathways between vanes while maintaining the simplified clustered assembly structure. The seals are integrated into the casting, creating effective barriers without complicating the assembly process.
3Adaptability or versatility
If gaps between vanes are present, then thermal expansion is accommodated, but thermal hot-spots are created on the engine case
Solution Approach 1:
The patent introduces thermal barrier coatings as intermediary protective layers between the hot gas path and the engine case structure. These coatings, applied to the forward and aft surfaces of the vane cluster, act as thermal mediators that reduce heat transfer to the case, preventing hot-spot formation while allowing the structure to accommodate thermal expansion.
4Strength
If complex machined features are used for vane attachment, then secure attachment is achieved, but manufacturing complexity and cost increase
Solution Approach 1:
The patent replaces traditional mechanical attachment systems (hooks, screws, rivets, and complex machined features) with a direct cast-in attachment method. The attachment portions are formed directly during the casting process, eliminating the need for separate mechanical fastening components and reducing manufacturing complexity while maintaining secure attachment through the integral structure.
5Object-affected harmful factors
If additional heat shields are installed to protect against thermal hot-spots, then engine case protection is improved, but device complexity and weight increase
Solution Approach 1:
The patent employs thermal barrier coatings as a composite material solution that integrates thermal protection directly into the existing vane cluster structure. Rather than adding separate heat shield components, the coating forms a protective composite layer that reduces heat transfer to the engine case, maintaining protection functionality while avoiding additional complexity and weight.
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
The integrated CMC case/stator segment reduces thermal hot-spots, minimizes leakage, and enhances mechanical efficiency by providing a seamless, lightweight structure that maintains energy transfer efficiency and reduces the need for additional heat shields.
Implementation Method 1
using CMC materials for improved thermal resistance and structural integrity
Data Source
AI summary
A gas turbine engine (10) includes a compressor (14, 16), a combustor section (18), and a turbine (20,22). The turbine includes an integrated case/stator segment (32A, 32B) that is comprised of a ceramic matrix composite material.