Turbine Engine Casing Preforms With Reinforced Angled Corners
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Solution Overview
Problem
Traditional two-dimensional layup designs for composite gas turbine engine components are challenging to manufacture and have limited interlaminar strength, with manually constructed flange corners prone to mechanical weakness and failure.
Innovation Solution
Integrating additional and larger fiber tows in the flange area of the casing structure during preforming, using three-dimensional weaving or braiding processes to enhance the strength of angled corners, replacing manual build-up and machining plies.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If traditional two-dimensional layup designs are used for composite gas turbine engine components, then manufacturing simplicity is maintained, but interlaminar strength and structural integrity are limited
Solution Approach 1:
The patent transitions from traditional two-dimensional layup designs to three-dimensional woven or braided fiber preforms. This dimensional change enables fibers to extend through the thickness of the component, creating continuous load paths and significantly improving interlaminar strength and structural integrity while maintaining manufacturing feasibility through automated preform placement processes
2Strength
If manually constructed flange corners are used in traditional composite components, then ease of assembly is maintained, but mechanical weakness and susceptibility to cracking occur
Solution Approach 1:
The patent integrates the flange corner region directly into the molded composite component using 3D woven or braided preforms that are co-cured with the main body. This merging eliminates manual assembly of flange corners, removing the weak interfaces between separate parts while maintaining ease of operation through integrated design and automated manufacturing processes
3Force
If additional and larger fiber tows are integrated in the flange area during preforming, then load-carrying capability is improved, but manufacturing process complexity increases
Solution Approach 1:
The patent implements local quality enhancement by integrating additional and larger fiber tows specifically in the flange area during the preforming process. This localized reinforcement concentrates material properties where highest stresses occur, maximizing load-carrying capability while managing overall manufacturing complexity through targeted rather than universal reinforcement
Solution Approach 2:
The patent incorporates additional fiber tows in the flange area during the preforming stage, before final molding and curing. This preliminary action ensures that reinforcement fibers are properly positioned and integrated into the preform structure, enabling the flange corners to withstand high loads during subsequent processing and operation without requiring post-assembly reinforcement
Data Source
Figure 1
Figure 2
Figure 3A~3C
AI summary
A preform (300) for making a casing structure (201) for turbine engines (10). The preform (300) includes a plurality of reinforcing fiber tows (302, 304, 306) arranged in a two-dimensional weave structure, a three-dimensional weave structure, or a braided structure. The plurality of reinforcing fiber tows (302, 304, 306) include integrally woven or braided fiber tows (306) having a diameter or a density greater than a respective diameter or a density of other woven or braided fiber tows (302, 304) in the two-dimensional weave structure, the three-dimensional weave structure, or the braided structure. The integrally woven or braided fiber tows (306) are located in an area of the preform (300) that is bent to form an angled corner (202A) to thereby provide strength to a casing structure (201) comprising the angled corner (202A).