Separate Airfoil Assembly Design for CMC Nozzle Fairings
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Solution Overview
Problem
The manufacturing of ceramic matrix composite (CMC) turbine nozzle fairings for gas turbine engines is hindered by complex shapes, long manufacturing cycles, low yield, poor compaction, and thermal stresses due to the integral formation of airfoil and band sections, leading to defects and leakage issues.
Innovation Solution
A separate airfoil assembly design where the airfoil, inner band, and outer band are formed as individual components with complementary openings and secured by fasteners, allowing for radial support and thermal expansion accommodation, reducing manufacturing complexity and stress.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If the airfoil, inner band, and outer band are integrally formed as one single component, then the structural integrity is improved, but the manufacturing complexity increases and manufacturing cycle time increases
Solution Approach 1:
The airfoil assembly is divided into separate components: the airfoil is formed independently from the inner band and outer band. Each component can be manufactured separately using conventional molding processes, then assembled together with the airfoil received within openings defined by the bands. This segmentation reduces manufacturing complexity while maintaining structural integrity through proper interface design.
2Stability of the object's composition
If the airfoil, inner band, and outer band are integrally formed as one single component, then the structural integrity is improved, but the manufacturing cycle time increases
Solution Approach 1:
By separating the airfoil from the bands, each component can be manufactured in parallel using independent molding processes, significantly reducing the total manufacturing cycle time. The airfoil is formed separately, then assembled with the inner and outer bands, eliminating the need for time-consuming integral formation while maintaining structural integrity.
3Stability of the object's composition
If the airfoil, inner band, and outer band are integrally formed as one single component, then the structural integrity is improved, but the manufacturing yield decreases
Solution Approach 1:
Separate manufacturing of the airfoil and bands allows for independent quality control and reduces defects. Each component can be inspected and repaired separately, increasing overall manufacturing yield. The assembly process then combines the individually manufactured components, maintaining structural integrity while improving productivity.
4Stability of the object's composition
If the airfoil and bands are integrally formed, then the structural integrity is improved, but thermal stresses increase due to thermal fight between components
Solution Approach 1:
The airfoil and bands are formed as separate components with different thermal expansion characteristics. This segmentation allows each component to expand and contract independently in response to temperature changes, reducing thermal stresses that would otherwise develop in an integral structure. The interface design accommodates these differential thermal movements.
5Ease of manufacture
If the airfoil assembly uses separate components with complementary openings, then the ease of manufacture is improved, but the device complexity increases due to multiple fastening requirements
Solution Approach 1:
The airfoil is formed as a separate component with complementary openings that fit within the inner and outer bands. This segmentation simplifies manufacturing by allowing conventional molding processes to be used for each component independently. The assembly process uses the complementary geometry to align and secure components, reducing the need for complex fastening mechanisms while maintaining ease of manufacture.
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 design simplifies the manufacturing process, increases yield, reduces defects, and eliminates split line leakage, enhancing the producibility and acceptability of CMC nozzle fairings while accommodating thermal expansion differences.
Implementation Method 1
an inner band defining an inner opening shaped complementary to the inner end of the airfoil and an outer band defining an outer opening shaped complementary to the outer end of the airfoil. The inner end of the airfoil is received with the inner opening and the outer end of the airfoil is received within the outer opening.
Implementation Method 2
a strut extending radially through a cavity defined by the airfoil, as well as a first pad defined at a first radial location within the cavity and a second pad defined at a second radial location within the cavity.
Data Source
AI summary
Airfoil assemblies for gas turbine engines are provided. For example, an airfoil assembly comprises an airfoil, an inner band defining an inner opening shaped complementary to an inner end of the airfoil, and an outer band defining an outer opening shaped complementary to an outer end of the airfoil. The airfoil inner end is received with the inner opening, and the airfoil outer end is received within the outer opening. A strut extends radially through an airfoil cavity. A first pad is defined at a first radial location within the cavity. A second pad is defined within the cavity at a second, different radial location. In some embodiments, the airfoil assembly inner band includes a first inner flange, through which the inner band is secured to a support structure, and the outer band includes a first outer flange, through which the outer band is secured to a support structure.