Segmented Ceramic-Matrix Composite Blade Track for Gas Turbine Engines
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Solution Overview
Problem
Design and manufacture of blade tracks in gas turbine engines from composite materials like ceramic-matrix composites present challenges, particularly in minimizing gas leakage and ensuring reliable bonding for efficient operation.
Innovation Solution
A full-hoop blade track design featuring segments with a tongue and groove interface and a layer of bonding material, where each segment is made from ceramic-matrix composite materials, with biscuits extending into blind slots for enhanced bonding and structural integrity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If blade tracks are made from ceramic-matrix composite materials, then gas leakage is reduced, but manufacturing complexity increases
Solution Approach 1:
The blade track is divided into multiple segments that can be manufactured separately and then assembled together using tongue-and-groove interfaces and bonding material. This segmentation allows each segment to be produced with standard manufacturing processes while the assembly process creates the complete functional blade track structure, reducing overall manufacturing complexity compared to producing a single monolithic ceramic-matrix composite component.
Solution Approach 2:
The blade track utilizes ceramic-matrix composite materials that combine ceramic fibers or particles within a matrix material to achieve superior gas leakage resistance. The composite structure provides both the desired gas sealing properties and structural integrity, allowing the blade track to function effectively in high-temperature gas turbine environments while maintaining manufacturability through modular assembly.
2Object-affected harmful factors
If blade tracks are designed as full-hoop segments, then gas leakage is minimized, but bonding reliability becomes more critical
Solution Approach 1:
The full-hoop blade track is segmented into multiple sections that can be independently manufactured and then joined together. Each segment includes tongue-and-groove features that guide the assembly process and ensure proper alignment, while the segmented design allows for the incorporation of bonding material at specific interfaces to create reliable connections that maintain gas sealing effectiveness.
Solution Approach 2:
Bonding material is introduced as an intermediary substance at the interfaces between blade track segments. This bonding material fills the gaps between segments, creates strong adhesive bonds, and ensures the integrity of the assembled blade track. The intermediary bonding material is crucial for maintaining gas leakage prevention while accommodating the modular segmented design.
3Manufacturing precision
If tongue and groove interfaces are used, then assembly precision is improved, but manufacturing steps increase
Solution Approach 1:
The blade track is divided into segments with integrated tongue-and-groove features that provide self-alignment during assembly. The tongue portion of one segment fits into the groove portion of the adjacent segment, automatically positioning the components relative to each other. This self-aligning mechanism improves assembly precision without requiring complex external positioning fixtures or procedures.
Solution Approach 2:
The tongue-and-groove interface combines multiple functions into a single integrated feature: it provides mechanical interlocking, self-alignment, and guidance for the assembly process. By merging these functions into one design element rather than using separate alignment pins, positioning fixtures, and bonding procedures, the overall manufacturing complexity is reduced while maintaining high assembly precision.
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
The solution effectively reduces gas leakage and enhances the structural strength of blade tracks, allowing for improved performance and manufacturing tolerances in gas turbine engines.
Implementation Method 1
a layer of bonding material arranged at an interface formed circumferentially between the first segment and the second segment to fix the first segment to the second segment
Data Source
AI summary
A blade track for a gas turbine engine includes segments and joints that couple the segments together. Each segment extends part-way around a central axis of the engine and the joints couple together adjacent segments to form a full hoop.