3D Woven Stator Vane Monobloc Fabrication
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Solution Overview
Problem
The existing manufacturing process for stator vanes in turbomachines is complex and costly due to the assembly of separate blade and platform parts, which results in a fragile connection and poor force transmission, especially at the right-angle junction, leading to increased manufacturing costs and reduced mechanical strength.
Innovation Solution
A method of 3D weaving a single-piece fiber preform with a first part forming the blade and a second part forming the platform, where the second part is produced in two layers that are separated by untying without cutting, allowing for continuous fibrous elements and overlap to enhance mechanical strength and solidity, and then densified with a polymer matrix.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If separate blade and platform parts are assembled to form the stator vane, then manufacturing flexibility is improved, but mechanical strength and connection reliability deteriorate at the blade-platform junction
Solution Approach 1:
The patent merges the blade and platform into a single monobloc component manufactured through 3D weaving of continuous fibrous elements. This eliminates the need for assembly operations and associated joining elements (cores, reinforcements, inserts), thereby resolving the contradiction by achieving both manufacturing efficiency and superior mechanical strength through integral construction.
Solution Approach 2:
The patent employs composite materials consisting of continuous fibrous elements (carbon, glass, or Kevlar fibers) woven in three dimensions to create a monobloc structure. This composite approach enables the blade and platform to be manufactured as one piece with enhanced mechanical properties, particularly at the junction area where stress concentration occurs in assembled structures.
2Strength
If additional reinforcement elements are added at the blade-platform connection, then mechanical strength is improved, but device complexity and manufacturing cost increase
Solution Approach 1:
The patent eliminates the need for separate reinforcement elements by integrating the blade and platform into a monobloc structure. The continuous fibrous elements extend seamlessly through the blade-platform junction, providing inherent structural reinforcement without requiring additional cores, inserts, or assembly operations, thus reducing device complexity while maintaining or enhancing connection strength.
3Ease of manufacture
If traditional assembly methods are used for blade and platform, then manufacturing process is simpler, but force transmission and structural integrity deteriorate
Solution Approach 1:
The patent combines the blade and platform into a single monobloc component manufactured by 3D weaving continuous fibrous elements. This integral construction ensures continuous load paths and superior force transmission through the blade-platform junction, eliminating the weak connections inherent in traditional assembled structures while maintaining manufacturing efficiency through automated weaving processes.
4Adaptability or versatility
If separate parts are assembled to form the stator vane, then adaptability in design is improved, but manufacturing precision and structural uniformity deteriorate
Solution Approach 1:
The patent merges the blade and platform into a monobloc structure manufactured through 3D weaving, which inherently provides superior structural uniformity and manufacturing precision. The continuous fibrous elements and automated weaving process eliminate assembly tolerances and junction irregularities, while design adaptability is maintained through the flexibility of 3D weaving patterns and material selection.
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 results in improved mechanical strength and reduced residual stresses at the blade-platform junction, enabling better force transmission and a more solid connection, while simplifying the manufacturing process and reducing costs.
Implementation Method 1
Under temperature and pressure conditions established in the enclosure, the gaseous phase diffuses within the preform, and is transformed into polymer on contact with the fibers of the preform
Implementation Method 2
the liquid precursor is injected into the mold at several points until the entire mold is filled (RTM process)
Implementation Method 3
Under the action of the vacuum, the precursor diffuses throughout the preform, then is polymerized by heat treatment to solidify it
Implementation Method 4
the precursor diffuses throughout the preform, then is polymerized by heat treatment to solidify it
Data Source
Figure 1A
Figure 1B
Figure 1C~1D
AI summary
The invention relates to a method for manufacturing a stator vane. Said method includes: developing, by 3D weaving into a single part, a fibrous preform (1) including a first portion (10) extending along a longitudinal axis (A) and consisting of the preform of the blade of said vane and, on one longitudinal end (11) of said first portion (10), a second portion (20) forming the preform of the platform of said vane, the second portion (20) being developed into a first layer (40) and a second layer (50) facing the first layer and separated from said first layer (40) by releasing without cutting during the development of said preform (1); folding the first layer (40) and the second layer (50) such that each is in a plane perpendicular to said longitudinal axis substantially symmetrical to each other relative to said first portion (10), and such that a first region (Ri) of the first layer (40) covers a second region (R2) of the second layer (50) in front of a front edge (15) of said first portion (10); shaping said preform (1) in a mold; and densifying said preform (1) with a polymer matrix.