Gas Turbine Stator Vane Assembly Design
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Solution Overview
Problem
Laminated ceramic matrix composite vanes in gas turbine engines face challenges such as inconsistent laminate thickness, limited bend radius without cracking, difficult coupling with platforms, and high interlaminar tension stresses, making them hard to attach and inspect, as well as controlling resonant frequencies.
Innovation Solution
A vane assembly design featuring separate pressure and suction side shells with ergonomic contours and a clamping member to maintain alignment and structural loading, facilitating efficient attachment and reducing resonant frequencies by minimizing interlaminar stresses.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a laminated ceramic matrix composite vane is used, then high temperature resistance and structural integrity are improved, but manufacturing complexity and difficulty of attachment increase due to inconsistent laminate thickness and limited bend radius
Solution Approach 1:
The vane is divided into multiple laminated layers that can be manufactured separately and then assembled. This segmentation allows each layer to be optimized for specific thickness requirements and reduces the complexity of manufacturing the entire vane as a single monolithic piece, directly addressing the inconsistent laminate thickness issue while maintaining structural integrity.
Solution Approach 2:
The patent modifies the physical parameters of the ceramic matrix composite, specifically adjusting laminate thickness variations and bend radius constraints. By controlling these parameters during manufacturing and design, the material maintains its high temperature resistance and strength while becoming more manufacturable and easier to attach to turbine platforms.
2Strength
If integral platforms are used to attach the vane, then attachment strength is improved, but interlaminar tension stresses increase during transition from vane to platform
Solution Approach 1:
A transition structure or intermediary component is introduced between the vane and the integral platform. This intermediary element gradually transitions the structural configuration, distributing the interlaminar tension stresses over a larger area and reducing peak stresses during the transition zone, while still maintaining strong attachment to the platform.
Solution Approach 2:
The patent applies different structural qualities to different regions of the vane-platform interface. The attachment region maintains integral platform characteristics for strength, while the transition zone incorporates modified laminate arrangements or stress-distributing features that locally reduce interlaminar tension stresses.
3Ease of manufacture
If non-integral platforms are used, then attachment complexity is reduced, but structural attachment capability deteriorates
Solution Approach 1:
The patent employs composite material strategies at the vane-platform interface, combining ceramic matrix composite vane sections with platform attachment features. This composite approach allows non-integral platform design for reduced complexity while maintaining structural attachment capability through optimized material interfaces and connection mechanisms.
4Ease of operation
If the vane is installed in the combustor, then operational function is achieved, but inspection difficulty increases
Solution Approach 1:
The patent incorporates visual indicators or markers on the vane surface that change color or provide visual contrast under operational conditions. These indicators allow for easier detection and inspection of the vane's condition, integrity, and position while it is installed in the combustor, reducing inspection difficulty without compromising operational function.
Data Source
AI summary
A gas turbine stator includes a vane assembly, and a platform that is configured to receive the vane assembly. The vane assembly includes a vane and a cap. The vane extends radially from the cap. The vane includes a pressure side shell and a separate suction side shell.