Monolithic Composite Blade and Platform for Gas Turbines
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Solution Overview
Problem
Existing gas turbine engines require additional process steps and sealing methods for airfoil-platform assemblies, which can reduce efficiency due to leaks and increased complexity.
Innovation Solution
A monolithic composite component for gas turbine engines is developed, featuring a continuous fiber blade with an airfoil and a platform made of chopped fibers, both embedded with a thermoplastic polymer. The components are coupled to form a single, irreversibly bonded unit, reducing the number of assembly steps and potential leaks.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If airfoils and platforms are formed separately and removably coupled together, then manufacturing flexibility is improved, but assembly complexity and potential leaks increase
Solution Approach 1:
The airfoil and platform are merged into a single monolithic composite component formed by molding chopped fibers and thermoplastic polymer together. This eliminates the need for separate assembly steps, bonding operations, and sealing between components, directly reducing assembly complexity while maintaining manufacturing flexibility through the molding process.
2Ease of manufacture
If separate components are used with bonding or fastening, then manufacturing flexibility is improved, but the number of process steps increases
Solution Approach 1:
The airfoil and platform are combined into one monolithic component through simultaneous molding of chopped fibers and thermoplastic polymer, eliminating multiple process steps including secondary bonding or fastening operations that would otherwise be required.
Solution Approach 2:
The chopped fibers and thermoplastic polymer are prepared and positioned in the mold before molding, allowing the entire airfoil-platform assembly to be formed in a single operation rather than requiring subsequent assembly steps.
3Reliability
If sealing is required between components, then connection integrity is improved, but efficiency is reduced due to leaks
Solution Approach 1:
By forming the airfoil and platform as a single monolithic composite component, the invention eliminates all interfaces between components, thereby eliminating sealing requirements and potential leak paths that would cause energy loss, while maintaining connection integrity through the continuous composite structure.
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 monolithic composite component reduces the number of assembly steps and seals required, potentially increasing the efficiency of the gas turbine engine by minimizing leaks and simplifying the manufacturing process.
Implementation Method 1
a thermoplastic polymer contained in both the continuous fiber blade and the platform
Data Source
AI summary
A component for a gas turbine engine. The component includes a continuous fiber blade including an airfoil extending radially between a root and a tip and a blade attachment feature positioned at or adjacent to the root. The component further includes a platform coupled to the root of the continuous fiber blade. The platform includes a plurality of chopped fibers. Additionally, the component includes a thermoplastic polymer contained in both the continuous fiber blade and the platform. Moreover, the continuous fiber blade and platform are coupled together such that the continuous fiber blade and platform form a monolithic composite body.