Turbine Containment System Using Composite Layers
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Solution Overview
Problem
Gas turbine engines face challenges in containing broken rotor blades and disks due to high centrifugal forces, which can lead to bursting, and existing containment systems are complex and costly, increasing manufacturing costs and weight.
Innovation Solution
A turbine containment system comprising a first containment member, such as an active clearance control casing, and a second containment member, including a Kevlar wrap and a soft wall hoop member, along with a high temperature hard wall casing, that together surround and protect rotor disks and blades, with a spoke mount connection to control thermal movement and a cooling air source to manage temperature.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the housing walls are manufactured to be relatively thick and reinforced with metal or other suitable materials to contain broken blades, then the containment reliability is improved, but the engine weight and manufacturing cost increase
Solution Approach 1:
The containment system is divided into multiple functional layers: an inner ACC casing for thermal management and primary containment, an intermediate barrier for additional protection, and an outer composite housing for structural support. This segmentation allows each layer to be optimized for its specific function rather than requiring a single thick reinforced wall, reducing overall weight while maintaining containment reliability.
Solution Approach 2:
The patent employs composite material construction for the outer housing, combining materials with different properties to achieve both strength and weight reduction. The composite structure provides adequate containment capability while being lighter than traditional solid metal reinforcement, directly addressing the weight-reliability contradiction.
2Temperature
If external piping systems are added to cool the casing and maintain proper temperature, then the temperature control effectiveness is improved, but the device complexity and manufacturing cost increase
Solution Approach 1:
The cooling function is merged with the containment structure itself. The ACC casing serves dual purposes: as part of the containment system and as a cooling air distribution pathway. Cooling air is introduced directly into the containment system, eliminating the need for separate external piping systems and reducing overall device complexity while maintaining effective temperature control.
Solution Approach 2:
The containment casing is designed to perform multiple functions simultaneously: structural containment of broken blades, thermal management through integrated cooling air flow paths, and clearance control. This multi-functionality eliminates the need for separate dedicated cooling piping systems, reducing complexity while achieving effective temperature control.
3Strength
If traditional thick-walled containment systems are used to withstand centrifugal forces, then the containment strength is improved, but the weight and manufacturing cost increase
Solution Approach 1:
The containment system segments the strength requirements across multiple components working together. The ACC casing, intermediate barrier, and outer housing each contribute to withstanding centrifugal forces, allowing thinner individual walls compared to a single thick-walled design. This segmented approach reduces manufacturing complexity and cost while maintaining overall containment strength.
Solution Approach 2:
Composite material construction provides high strength-to-weight ratio, enabling the containment system to withstand centrifugal forces from broken blades without requiring thick metal walls. The composite structure reduces manufacturing cost and complexity compared to traditional solid metal reinforcement while maintaining adequate strength.
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
Effectively contains rotor blades and disks, reducing the risk of bursting and minimizing weight and manufacturing costs by using a lightweight, thermally controlled containment system that manages centrifugal forces and temperature effectively.
Implementation Method 1
a first flow of cooling fluid from the cooling air source is directed through the active clearance control casing and the apertures of the shield to the turbine
Implementation Method 2
a spoke mount connection between the active clearance control casing and the second containment member to control thermal movement therebetween
Data Source
AI summary
A turbine containment system is provided. The turbine containment system includes a first containment member surrounding a portion of a turbine including a plurality of rotor disks and rotor blades; and a second containment member in communication with the first containment member, wherein the first containment member and the second containment member together contain each of the rotor disks and the rotor blades therein.