Non-Crimped Ceramic Matrix Composite for Gas Turbine Engines
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Solution Overview
Problem
Ceramic matrix composites used in gas turbine engines face limitations in strength and durability due to crimped fiber weave patterns, which lead to non-uniform load distribution and reduced mechanical and thermal properties, necessitating improved material designs for high-temperature applications.
Innovation Solution
A ceramic matrix composite fabrication method utilizing non-crimped fiber layers oriented in parallel, stitched with small elastic fibers, and infiltrated with a ceramic matrix, such as silicon carbide, to enhance tensile response and inter-laminar properties, reducing off-axis loading and improving uniformity and strength.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If crimped fiber weave patterns are used in ceramic matrix composites, then the composite can be manufactured with traditional weaving techniques, but the load distribution becomes non-uniform and mechanical strength is reduced
Solution Approach 1:
The patent changes the geometric parameter of fiber arrangement from crimped weave pattern to non-crimped straight parallel arrangement. This parameter change eliminates the non-uniform load distribution caused by fiber crimping while maintaining manufacturability through automated fiber placement techniques, thereby resolving the contradiction between ease of manufacture and mechanical strength
Solution Approach 2:
Instead of using traditional crimped weave patterns that are easy to manufacture but weak, the patent inverts the approach by using non-crimped straight fiber arrangements that are difficult to manufacture traditionally but can be achieved through automated placement, thus prioritizing strength while maintaining manufacturability through new methods
2Ease of manufacture
If crimped fiber weave patterns are used in ceramic matrix composites, then the composite structure is simpler to fabricate, but thermal properties and uniformity are reduced
Solution Approach 1:
The patent changes the fiber arrangement parameter from crimped to non-crimped straight parallel configuration, which eliminates the non-uniformity inherent in woven structures. This parameter change improves material uniformity and thermal properties while maintaining fabrication capability through automated fiber placement processes
3Strength
If non-crimped fiber layers are used instead of crimped weave patterns, then load distribution becomes more uniform and mechanical strength increases, but manufacturing complexity increases
Solution Approach 1:
The patent replaces the traditional mechanical weaving system with an automated fiber placement system that uses computer-controlled deposition of fibers in straight parallel arrangements. This substitution eliminates the need for complex weaving operations while achieving superior non-crimped fiber architecture, thus resolving the contradiction between mechanical strength and manufacturing complexity
Solution Approach 2:
The patent changes the manufacturing approach from traditional weaving to automated fiber placement, altering the process parameters to achieve non-crimped straight fiber arrangements. This parameter change improves mechanical strength through uniform load distribution while managing manufacturing complexity through automation and computer control
Data Source
AI summary
A novel ceramic matrix composite is disclosed for forming components that are operable in high temperature environments such those in gas turbine engines and the like. The ceramic matrix composite can include at least one layer of non-crimped fibers positioned substantially parallel to one another. A relatively small diameter elastic fiber can be constructed to stitch the non-crimped fibers together and a ceramic matrix may be deposited around the at least one layer of non-crimped fibers.