Iso-grid Composite Component for Gas Turbine Nozzles
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Solution Overview
Problem
Convergent/divergent nozzles in gas turbine engines face challenges with weight and design space requirements due to the use of carbon fiber composite materials in flaps and seals, which can lead to internal thermal issues and delamination.
Innovation Solution
The iso-grid composite component design utilizes uni-tape ply bundles and spacers to form lateral and longitudinal ribs, alternating their heights to prevent internal thermal fights and maintain constant height, thereby reducing weight and increasing robustness, and uses interstitial ply layers to separate ribs and accommodate thermal expansion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If carbon fiber composite materials with monocoque constructions or hollow rib reinforcements are used in flaps and seals, then structural strength is improved, but weight and design space requirements increase
Solution Approach 1:
The component is divided into a monocoque construction and separate reinforcement elements (ribs or stiffeners) that are added on. This allows the base structure to be lightweight while reinforcements provide additional strength only where needed, rather than requiring the entire structure to be thick and heavy.
Solution Approach 2:
Reinforcements are applied locally at specific positions where structural strength is needed, rather than uniformly throughout the entire component. This targeted approach provides necessary strength while minimizing additional weight and design space requirements.
2Strength
If carbon fiber composite materials with monocoque constructions or hollow rib reinforcements are used in flaps and seals, then structural strength is improved, but design space requirements increase
Solution Approach 1:
The component is divided into a monocoque construction and separate reinforcement elements (ribs or stiffeners) that are added on. This allows the base structure to be compact while reinforcements provide additional strength only where needed, rather than requiring the entire structure to be thick and heavy.
Solution Approach 2:
The reinforcement elements are integrated into the existing component structure in a space-efficient manner, with ribs or stiffeners positioned within or along the contours of the monocoque construction, maximizing structural efficiency within limited design space.
3Stability of the object's composition
If traditional composite constructions are used in flaps and seals, then structural integrity is maintained, but internal thermal fights and delamination occur
Solution Approach 1:
An intermediate layer or interface treatment is introduced between the monocoque construction and reinforcement elements to manage thermal expansion differences and prevent delamination. This intermediary layer accommodates thermal stresses while maintaining structural integrity.
Solution Approach 2:
The thermal and mechanical parameters of the composite construction are optimized by selecting materials and designs that accommodate thermal expansion and contraction, preventing internal thermal fights that lead to delamination and structural failure.
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 design results in a lighter, more compact, and robust component that prevents delamination and internal destruction, enhancing the performance and durability of variable geometry C/D exhaust nozzles.
Implementation Method 1
uses interstitial ply layers to separate ribs and accommodate thermal expansion
Data Source
Figure 1
Figure 2
Figure 3~4
AI summary
An iso-grid composite component (50) includes a spacer (72) transverse to a uni-tape ply bundle (70), the spacer (72) interrupted by the uni-tape ply bundle (70). The uni-tape ply bundles (70) and spacers (72) form ribs (60,62) of the component (50).