Gas Turbine Liner Panel Bushing Remanufacturing
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Solution Overview
Problem
Gas turbine engine liner panels, particularly those with metallic bushings, experience wear due to vibrations, leading to reduced service life and the need for effective repair or remanufacturing methods.
Innovation Solution
A method involving the removal of damaged metallic bushings from liner panels, followed by abrasive blasting with plastic media, and subsequent molding with a carbon fiber-based sheet molding compound material, such as Lytex 4149, using a multi-layered material charge with specific width ratios to create a strong and vibration-resistant panel.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If metallic bushings are used in liner panels, then the panels can be manufactured with standard materials and processes, but the panels experience wear from vibration leading to reduced service life
Solution Approach 1:
The patent applies composite materials by integrating carbon fiber reinforced plastic (CFRP) bushings directly into the liner panel during the molding process. This creates a composite structure where the CFRP bushing combines the wear resistance of carbon fiber with the structural integrity of the panel, eliminating the wear problem associated with metallic bushings while maintaining ease of manufacture through integrated molding.
Solution Approach 2:
The patent changes the material parameters of the bushing from metallic to carbon fiber reinforced plastic. This parameter change provides superior vibration resistance and wear resistance while maintaining the structural requirements. The CFRP material offers a different mechanical property profile that resolves the service life issue without compromising manufacturability.
2Reliability
If the entire liner panel is replaced when bushings wear out, then the bushing wear problem is solved, but the cost and time increase due to replacing serviceable components
Solution Approach 1:
The patent applies local quality by making only the bushing component from wear-resistant carbon fiber reinforced plastic while the rest of the liner panel can be made from standard materials. This localized application of enhanced material properties allows the bushing to resist wear independently, enabling selective replacement or extended service life without requiring complete panel replacement, thus reducing downtime.
Solution Approach 2:
The patent extracts the bushing function from the main panel structure by creating a separately moldable bushing component that can be independently replaced. The bushing is designed as a distinct element within the composite structure, allowing it to be removed and replaced without discarding the entire panel, thereby solving the wear problem while minimizing time loss.
3Ease of manufacture
If traditional molding processes are used, then the manufacturing process is simple, but the vibration resistance and strength of the panel are insufficient
Solution Approach 1:
The patent uses composite materials (carbon fiber reinforced plastic) to create bushings with superior vibration resistance and strength. The CFRP material provides enhanced mechanical properties including higher stiffness and fatigue resistance compared to traditional materials, while the molding process remains relatively simple and integrated into the existing manufacturing workflow.
Solution Approach 2:
The patent changes the material parameters by using carbon fiber reinforced plastic with specific fiber orientations and resin systems to achieve optimal vibration resistance. The material composition and structural parameters of the bushing are optimized to withstand vibrational loads while maintaining compatibility with standard molding processes.
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 solution results in higher vibration resistance and optimal strength, extending the service life of the liner panels by using a carbon fiber-based material charge with a defined discontinuity ratio, facilitating improved mechanical properties and durability.
Implementation Method 1
removing the bushing from the damaged component by abrasive blasting
Data Source
AI summary
A method of remanufacturing a liner panel for a gas turbine engine includes removing a bushing from a damaged component; and molding the bushing with a material charge. A liner panel for a gas turbine engine includes a forward fan exit case liner panel with a donor bushing from a damaged forward fan exit case liner panel. A liner panel for a gas turbine engine includes a forward fan exit case liner panel molded from a material charge that includes a multiple of layers. At least one of the multiple of layer includes a discontinuity.