Kerfed Conformable Membrane for Gas Turbine Erosion

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Solution Overview

Problem

Laminate polymer matrix composites used in gas-turbine engines lack erosion resistance and require coatings that are limited by high temperature usage and cannot be applied using traditional spraying or tank dipping methods.

Innovation Solution

A conformable solid membrane coating made from metallic or polymeric foils/films with a kerf pattern, allowing for flexibility and adherence to compound-curved surfaces, providing erosion and impact resistance while withstanding high temperatures.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If traditional erosion resistant coatings (elastomers) are used, then erosion resistance is improved, but maximum usage temperature is limited

Engineering Contradiction:

Improveerosion resistanceVSAvoidmaximum usage temperature

Core Design Contradiction:

ReliabilityVSTemperature

Solution Approach 1:

The patent uses a composite structure consisting of a polymer matrix composite airfoil with an erosion resistant coating layer. The coating is applied over the PMC substrate to provide erosion protection while the underlying PMC structure provides lightweight structural support, creating a composite system that combines the advantages of both materials.

Inventive Principle:

Principle #40Composite materials

2Ease of manufacture

If traditional spraying or tank dipping methods are used, then coating application is simple, but application to compound-curved surfaces is not feasible

Engineering Contradiction:

Improvecoating application simplicityVSAvoidapplicability to compound-curved surfaces

Core Design Contradiction:

Ease of manufactureVSAdaptability or versatility

Solution Approach 1:

The coating membrane is divided into multiple segments by kerfs (slits) that extend through its thickness. This segmentation allows the membrane to flex and conform to complex curved surfaces like airfoils while maintaining structural integrity. The kerfs act as hinges that enable the rigid-looking membrane to adapt to three-dimensional contours.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The patent employs a thin membrane structure with kerfs that provides flexibility and conformability to compound-curved surfaces. The membrane is thin enough to drape over complex geometries but thick enough to provide erosion protection, creating a flexible shell that can be applied to airfoils and other curved components.

Inventive Principle:

Principle #30Flexible shells and thin films

3Weight of moving object

If laminate polymer matrix composites are used, then weight is reduced, but erosion resistance is insufficient

Engineering Contradiction:

Improveairfoil weightVSAvoiderosion resistance

Core Design Contradiction:

Weight of moving objectVSReliability

Solution Approach 1:

The solution creates a composite structure where the lightweight polymer matrix composite provides the primary structural function and weight savings, while an additional erosion resistant coating layer provides protection against particle impact and erosion. This composite approach allows the airfoil to maintain low weight while gaining erosion resistance.

Inventive Principle:

Principle #40Composite materials

Data Source

PatentUS11408291B2Airfoil conformable membrane erosion coating

Publication Date: 2022.08.09 RTX CORP

AI summary

A coating membrane for a component of a gas-turbine engine includes a solid membrane having a metallic foil or a polymeric film, and having a thickness and at least one kerf extending through the thickness to define a kerf pattern such that the solid membrane can be applied to a compound-curved surface. Also disclosed are a coated component coated with the membrane, and a method for producing a coated component with the membrane.