Monolithic Gas Turbine Rotor Blade Design

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Solution Overview

Problem

Gas turbine engine designers face challenges in increasing turbine rotational speed while managing centrifugal loading and heat treating of rotor disk bores, which are exacerbated by the weight and structural complexities of current rotor blade designs, particularly with separate airfoils and interrupted features.

Innovation Solution

The development of a rotor blade and assembly configuration using a monolithic body with ceramic, metal, or intermetallic materials, featuring a forked body with a bridge and radially diverging legs, and incorporating seal and damper elements to minimize centrifugal loading and enhance structural integrity.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If separate airfoils with tooth attachments are used, then structural integrity is improved, but weight and device complexity increase

Engineering Contradiction:

Improvestructural integrityVSAvoidrotor blade weight

Core Design Contradiction:

StrengthVSWeight of moving object

Solution Approach 1:

The patent merges separate airfoils and disk into a single integrated rotor blade assembly. The monolithic structure eliminates the need for separate tooth attachments and cover plates while maintaining structural integrity through continuous material flow and optimized geometry.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The rotor blade is segmented into functional zones within a monolithic structure, with strategic voids and reinforcement zones positioned to optimize strength-to-weight ratio without requiring separate attachment components.

Inventive Principle:

Principle #1Segmentation

2Productivity

If turbine rotational speed is increased, then performance is improved, but centrifugal loading and heat treatment complexity increase

Engineering Contradiction:

Improveturbine performanceVSAvoidheat treatment complexity

Core Design Contradiction:

ProductivityVSDevice complexity

Solution Approach 1:

The monolithic structure enables optimized material distribution and geometric parameters that reduce centrifugal stresses at high rotational speeds. The integrated design allows for controlled material properties and heat treatment parameters throughout the structure, simplifying the heat treatment process while enabling higher turbine speeds.

Inventive Principle:

Principle #35Parameter changes

3Adaptability or versatility

If separate airfoils with attachment features are used, then adaptability is improved, but device complexity and weight increase

Engineering Contradiction:

Improvedesign flexibilityVSAvoidattachment feature complexity

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The monolithic rotor blade structure performs multiple functions simultaneously: structural support, aerodynamic function, and stress distribution. The integrated design eliminates the need for separate attachment features while maintaining adaptability through optimized geometric parameters and material distribution.

Inventive Principle:

Principle #6Universality (Multi-functionality)

Data Source

PatentEP3851639B1Rotor blade and rotor assembly for a gas turbine engine

Publication Date: 2023.06.28 RTX CORP

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AI summary

A rotor blade is provided for a gas turbine engine. This rotor blade includes a rotor blade pair (42) including a mount (38), a first airfoil (40A) and a second airfoil (40B). The mount includes a forked body with a first leg (50A) and a second leg (50B). The first airfoil is connected to the first leg. The second airfoil is connected to the second leg and arranged circumferentially next to the first airfoil.