Gas Turbine Rotor Disk Composite Reinforcement
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Solution Overview
Problem
Existing rotor disks in gas turbine engines are heavy and bulky, requiring significant materials and space, and current fiber/composite-reinforced designs face challenges with complex manufacturing processes and interfacial stresses between materials.
Innovation Solution
A structurally-reinforced rotor disk design featuring a metallic body with an annular ring made from a composite material, such as an organic or metal matrix composite, wound circumferentially through an annular recess in the bore, which increases the self-sustaining radius without the need for mechanical fasteners.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If traditional metal rotor disks are used, then structural strength is sufficient, but weight and space requirements increase significantly
Solution Approach 1:
The patent applies composite materials by integrating ceramic fibers into the metallic rotor disk material. This composite approach allows the rotor disk to maintain sufficient structural strength while reducing weight and space requirements compared to traditional solid metal disks.
2Weight of moving object
If fiber/composite reinforcements are integrated during manufacturing, then weight reduction is achieved, but manufacturing complexity increases
Solution Approach 1:
The patent employs preliminary action by pre-forming annular recesses in the rotor disk during manufacturing, which are then filled with composite reinforcement materials. This approach simplifies the overall manufacturing process by preparing the structure in advance rather than requiring complex integrated fiber embedding procedures.
3Weight of moving object
If mechanical fasteners are used to attach composite reinforcement, then structural integrity is maintained, but weight reduction benefits are counteracted
Solution Approach 1:
The patent merges the composite reinforcement material directly with the rotor disk structure by filling annular recesses with composite material that bonds to the metal substrate. This integration eliminates the need for separate mechanical fasteners, maintaining structural integrity while preserving weight reduction benefits.
4Weight of moving object
If composite materials are used to reduce weight, then self-sustaining radius increases, but interfacial stress between materials increases
Solution Approach 1:
The patent uses an intermediary approach by introducing a bonding interface layer or treatment at the metal-composite interface. This mediator facilitates stress transfer between the metallic rotor disk and composite reinforcement, reducing interfacial stress concentrations while maintaining the weight reduction benefits of composite materials.
Data Source
AI summary
A structurally-reinforced rotor disk for a gas turbine engine is disclosed. The rotor disk may comprise a body including a rim configured to support airfoils (which may be separate or integral with the airfoils), an axially-extending bore disposed radially inward of the rim, and a radially-extending web connecting the rim and the bore. The bore may include an axial outer edge and at least one circumferentially-extending annular recess formed axially between the outer edge and the web. The rotor disk may further comprise an annular ring retained in the annular recess, and the annular ring may be formed from a different material than the body of the rotor disk so as to increase a self-sustaining radius of the rotor disk.