Morphing Ceramic Composite Hypersonic Wind Tunnel Throat
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Solution Overview
Problem
Current ground-based testing facilities for supersonic and hypersonic engine and vehicle technologies are limited by their inability to efficiently produce continuous testing over predetermined Mach ranges due to fixed Mach numbers and restrictive rectangular flow paths, which hinder optimal flow conditioning.
Innovation Solution
A morphable composite three-dimensional structure made of flexible fiber-reinforced ceramic composite with a variable cross-section along its length, coupled with actuators to alter the flowpath geometry, allowing for continuous Mach number variation and efficient air flow management.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If fixed Mach number facilities are used, then operational simplicity is maintained, but testing efficiency and adaptability across Mach ranges deteriorate
Solution Approach 1:
The patent implements a morphing throat structure that dynamically changes its geometry to adapt to different Mach numbers. The throat cross-section can be continuously adjusted during operation, transforming from a fixed configuration to a variable one, enabling the facility to efficiently test across a wide Mach range (Mach 3-8) without requiring multiple dedicated facilities
Solution Approach 2:
The wind tunnel facility is designed with universal applicability across multiple Mach ranges by incorporating the morphing throat. This single facility can serve multiple testing purposes from Mach 3 to Mach 8, covering transitions from turbine to ramjet to scramjet engines, eliminating the need for separate specialized facilities for each Mach range
2Manufacturing precision
If rectangular flow paths with flat plates are used, then manufacturing simplicity is maintained, but flow conditioning quality and aerodynamic performance deteriorate
Solution Approach 1:
The patent replaces traditional rectangular flow paths with curved, aerodynamically optimized cross-sections. The morphing throat features curved surfaces that evolve along the flow direction, providing superior flow conditioning and reduced shock losses compared to rectangular geometries with flat plates
Solution Approach 2:
The morphing throat utilizes flexible ceramic matrix composite materials that can be formed into complex curved geometries. These flexible composite structures enable the creation of smooth, continuous curved surfaces that would be difficult to manufacture using traditional rigid methods, achieving both manufacturing feasibility and aerodynamic performance
3Reliability
If sliding seals are used to contain hot gases, then flow path containment is achieved, but reliability and maintenance complexity deteriorate
Solution Approach 1:
The patent completely eliminates sliding seals from the flow path by using a monolithic ceramic matrix composite structure. The flexible composite material provides inherent flow containment through its structural integrity, removing the need for separate seal components and their associated complexity and reliability issues
Solution Approach 2:
The use of ceramic matrix composite materials provides both structural strength and flow containment in a single integrated component. These composites maintain integrity at high temperatures while providing the necessary containment, eliminating the need for additional sealing systems that would be required with traditional materials
4Productivity
If fixed geometry throats are used, then structural simplicity is maintained, but testing efficiency and Mach range coverage deteriorate
Solution Approach 1:
The throat structure transitions from a fixed geometry to a dynamic, morphing configuration that can continuously adjust its cross-section. This dynamic capability allows the facility to efficiently test across the entire Mach 3-8 range by optimizing the throat geometry for each Mach number, significantly improving testing productivity
Solution Approach 2:
The morphing throat is constructed from segmented or modular ceramic composite elements that can independently deform. This segmentation allows the complex morphing motion to be achieved through coordinated actuation of individual segments, making the structural complexity manageable while maintaining high testing efficiency
Data Source
AI summary
In one embodiment, a morphable composite three-dimensional structure is disclosed. The morphable composite three-dimensional structure comprises a flexible fiber-reinforced ceramic composite comprising a fiber preform and a ceramic matrix material infused therein. The flexible fiber-reinforced ceramic composite defines a flowpath having a three-dimensional cross-section. The cross-section of the flowpath is variable along the length of the flowpath. A plurality of anchors are integrally formed in the fiber preform. The plurality of anchors extend through a thickness of the ceramic matrix. The plurality of anchors are configured to couple to at least one actuator. The at least one actuator is actuatable to vary the three-dimensional cross-section of the flowpath.