Multi-Layer Woven Preforms for Complex Components Without Joins
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Solution Overview
Problem
Existing woven structures face challenges in forming complex components with integrated 3D weaves, particularly in gas turbine engines, due to difficulties in creating suitable cooling holes and potential internal ruptures during inadequate interlacing.
Innovation Solution
A multi-layer weave structure is developed, allowing for the creation of a woven preform with separable free leaves and varying weave types, enabling the formation of complex components without the need for post-weave joins, using a computer-controlled loom to produce a near net shape that can be infused with a matrix material.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If multi-layer weave structures are used to provide through-thickness structural integrity, then structural integrity is improved, but device complexity increases
Solution Approach 1:
The weave structure is segmented into multiple independent layers (first layer, second layer, third layer) with distinct functions. The first and third layers provide structural integrity with high areal density, while the second layer provides through-thickness reinforcement with z-directional tows. This segmentation allows each layer to be optimized independently while working together to achieve overall structural integrity.
Solution Approach 2:
The patent introduces z-directional tows (through-thickness tows) that extend perpendicular to the traditional warp and weft directions. This adds a third dimension to the conventional 2D weave structure, enabling reinforcement in the through-thickness direction without compromising the in-plane structural integrity provided by the first and third layers.
2Manufacturing precision
If computer-controlled looms are used to create diverse multi-weave structures, then manufacturing precision is improved, but device complexity increases
Solution Approach 1:
The weave structure is designed with predetermined patterns and configurations that are programmed into the computer-controlled loom before manufacturing. The loom controller executes pre-defined sequences to achieve the complex multi-layer weave pattern, ensuring precision while automating the complex coordination required for multi-layer weaving.
3Reliability
If adequate interlacing is performed to prevent internal rupture, then reliability is improved, but manufacturing time increases
Solution Approach 1:
The interlacing function is segmented across multiple layers, with each layer contributing to overall reliability. The first and third layers provide structural integrity through traditional warp-weft interlacing, while the second layer provides additional through-thickness interlacing. This distributed interlacing approach achieves adequate reinforcement without requiring excessive interlacing in a single layer, thereby reducing manufacturing time.
Data Source
Figure 1a~1b
Figure 1c
Figure 2a~2b
AI summary
A method for manufacturing a composite component, comprising: weaving a multi-layer woven preform 700 for the component from warp and weft tows of fibre-reinforcement material, so that the woven preform comprises: a multi-layer weave comprising: a plurality of weft tow layers,; a plurality of laterally-adjacent stacks S extending along the longitudinal direction, a primary portion 500 having a longitudinal extent along the woven preform, the primary portion having one or more edge regions 506, 508 each defining a respective lateral side of the primary portion; wherein for the or each edge region: the multi-layer weave defines at least the edge region; a plurality of stacks in the edge region are binding stacks in which one or more warp tows are interlaced to bind a respective plurality of weft tow layers; a weave property differs between binding stacks in the edge region to reduce a thickness of the edge region towards the respective lateral side. Also disclosed herein is a woven structure, formed by warp and weft tows of fibre reinforcement material.