Plated Polymer Fan for Gas Turbine Engine Weight Reduction
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Solution Overview
Problem
Current methods for producing lightweight metal parts for gas turbine engines are costly and inefficient, as they often require complex and expensive hard tooling, and traditional machining techniques can reduce material properties and are not suitable for composite materials with multiple layers or high-temperature applications.
Innovation Solution
The method involves molding a polymer article with a desired geometry and then plating it with metallic layers using electroless or electrolytic plating methods, allowing for the creation of lightweight, strong components that can withstand high temperatures and incorporate sound attenuation properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If traditional machining techniques are used to remove material from metal parts, then weight is reduced, but material properties are degraded and manufacturing cost increases
Solution Approach 1:
The patent replaces traditional mechanical machining processes with a molding process that forms metal parts directly in their final shape. This substitution eliminates material removal and associated damage to material properties while achieving the desired weight reduction through optimized part geometry and potential polymer substitution in non-critical areas.
Solution Approach 2:
The patent applies preliminary action by pre-forming parts with optimized geometry during the molding process itself, rather than starting with excess material that requires subsequent removal. This includes designing parts with material strategically placed only where needed for structural integrity, thereby reducing weight without requiring post-manufacturing material removal that would damage material properties.
2Manufacturing precision
If complex hard tooling is used for molding polymer parts, then manufacturing precision is improved, but device complexity and cost increase
Solution Approach 1:
The patent employs soft tooling made from flexible materials such as silicone rubber or thermoplastic elastomers, which are significantly simpler and less expensive than traditional hard metal tooling. These soft tools can be easily manufactured, modified, and discarded after limited use, eliminating the need for complex, expensive hard tooling while still achieving adequate manufacturing precision for the application.
Solution Approach 2:
The patent changes the physical parameters of the tooling material from rigid metal to flexible polymer materials. This parameter change allows the tooling to be simpler in construction while still achieving the required dimensional accuracy through the flexibility and conformability of the soft material, thereby reducing device complexity while maintaining manufacturing precision.
3Strength
If metal parts are used for high strength applications, then strength is improved, but weight increases
Solution Approach 1:
The patent utilizes composite materials, specifically polymer matrix composites reinforced with fibers or particles, to achieve the necessary strength properties while maintaining low weight. These composite materials combine the high strength-to-weight ratio of polymers with the reinforcing properties of additives, enabling parts to meet strength requirements without the weight penalty of solid metal construction.
Solution Approach 2:
The patent applies local quality by incorporating reinforcing materials selectively in specific regions of the polymer part where strength is needed, rather than uniformly throughout the entire part. This allows the part to achieve necessary strength properties in critical areas while maintaining overall lightweight construction in non-critical areas, optimizing the strength-to-weight ratio.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach enables the production of lightweight, cost-effective gas turbine engine components with improved strength and temperature resistance, while reducing noise and weight, and allows for complex geometries and short production runs without the need for expensive hard tooling.
Implementation Method 1
plating the outer surface of the polymer article with metallic layers using electroless plating, electrolytic plating, or electroforming methods
Implementation Method 2
plating the outer surface of the polymer article with metallic layers using electroless plating, electrolytic plating, or electroforming methods
Implementation Method 3
plating the outer surface of the polymer article with metallic layers using electroless plating, electrolytic plating, or electroforming methods
Data Source
AI summary
Plated polymeric gas turbine engine parts and methods for fabricating lightweight plated polymeric gas turbine engine parts are disclosed. The parts include a polymeric substrate plated with one or more metal layers. The polymeric material of the polymeric substrate may be structurally reinforced with materials that may include carbon, metal, or glass. The polymeric substrate may also include a plurality of layers to form a composite layup structure.