Non-Metallic Leading Edge Wrap for Composite Turbine Airfoils
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Solution Overview
Problem
Existing composite airfoils for turbine engines with metallic leading edge wraps face challenges such as detachment during operation, exposing the composite core to damage and potential downstream damage to other engine components.
Innovation Solution
The development of composite airfoils with non-metallic leading edge protective wraps, specifically a dual-wrap configuration comprising a trailing wrap and a leading wrap, both formed from fibrous composite materials, providing structural integrity and protection against erosion and Foreign Object Debris.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If a metallic leading edge wrap is used on a composite airfoil, then the leading edge is protected against erosion and FOD, but the wrap may detach during operation exposing the composite core to damage
Solution Approach 1:
The patent applies composite materials by using a non-metallic leading edge wrap made from fibrous composite material that is chemically compatible with the composite core. This composite construction eliminates galvanic corrosion and bonding failures that plague metallic wraps, ensuring the wrap remains reliably attached while providing protection against erosion and FOD.
Solution Approach 2:
The patent changes the material parameter from metallic to non-metallic fibrous composite material. This parameter change resolves the detachment issue by eliminating the galvanic corrosion and bonding failures inherent in metallic constructions, while maintaining the protective function against erosion and foreign object debris.
2Object-generated harmful factors
If a non-metallic leading edge protective wrap is used, then the risk of downstream damage is reduced, but the structural integrity and protection effectiveness must be maintained
Solution Approach 1:
The patent uses composite materials for both the wrap and core, creating a structurally integrated system where the non-metallic fibrous composite wrap maintains structural integrity while reducing downstream damage risk. The composite construction provides both strength and harm reduction simultaneously.
Solution Approach 2:
The patent applies homogeneity by using the same non-metallic fibrous composite material for both the leading edge wrap and the composite core. This material uniformity ensures compatible thermal and mechanical properties, maintaining structural integrity while eliminating galvanic corrosion and bonding failures.
3Object-affected harmful factors
If a dual-wrap configuration is used, then protection effectiveness is enhanced, but the device complexity increases
Solution Approach 1:
The patent applies segmentation by dividing the leading edge protection into two distinct wraps: an inner wrap directly bonded to the composite core and an outer wrap bonded to the inner wrap. This segmentation enhances protection effectiveness by creating layered defense against erosion and FOD, while the modular construction actually simplifies the manufacturing process compared to single-piece metallic wraps.
Solution Approach 2:
The dual-wrap configuration uses non-metallic fibrous composite materials for both layers, which simplifies the overall construction by eliminating complex metallic bonding requirements and corrosion protection measures. The composite material system makes the multi-layer configuration more manageable than equivalent metallic designs.
Data Source
AI summary
A composite airfoil having a non-metallic leading edge protective wrap is provided. In one aspect, the airfoil has a composite core having a pressure sidewall and a suction sidewall each extending between a core leading edge and a core trailing edge. A leading edge protective wrap protects the core leading edge and includes a trailing wrap and a leading wrap. The trailing wrap wraps around the core leading edge and is connected to the composite core. The leading wrap wraps around the core leading edge and is connected to the trailing wrap. The trailing and leading wraps both have leading edges that are spaced from one another. A filler is positioned between the leading edges of the trailing and leading wraps. A protective nose is connected to the leading edge of the leading wrap. The components of the leading edge protective wrap are formed of non-metallic materials.