Turbine Frame Fairing Brazed Segments Leakage
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Solution Overview
Problem
The mid-turbine frame fairings in gas turbine engines face challenges due to non-uniform deflections and potential leakage from segmented structures under thermal and pressure environments, which are exacerbated by the inability to weld and the high cost of large-scale castings.
Innovation Solution
A static structure comprising multiple airfoil segments brazed together to form an annular core flow, with structural reinforcement rings mounted on the airfoil segments to provide additional support and sealing, utilizing different braze materials for various joints to manage thermal and stress loads.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If segmented airfoil structures are used in mid-turbine frame fairings, then ease of manufacture is improved, but reliability deteriorates due to non-uniform deflections and potential leakage between segments
Solution Approach 1:
The airfoil structure is divided into multiple segments that can be manufactured separately and then assembled. This segmentation allows for easier manufacturing of individual components while maintaining the overall aerodynamic function of the fairing structure.
Solution Approach 2:
Brazing joints serve as intermediary connections between the airfoil segments. These brazed joints provide both structural continuity and sealing functionality, preventing leakage while accommodating thermal expansion and deflection differences between segments.
2Reliability
If brazed joints are used to connect airfoil segments, then reliability is improved by minimizing leakage, but manufacturing precision requirements worsen due to tight tolerances needed for proper brazing
Solution Approach 1:
The brazing joints are designed with specific local geometries and material properties tailored to the sealing and structural requirements at each joint location. This allows for optimized sealing performance without requiring extremely tight tolerances across the entire structure.
Solution Approach 2:
The brazing process utilizes composite material systems including base metal, filler metal, and potentially intermediate layers that accommodate tolerance variations while providing both structural strength and leakage prevention.
3Strength
If structural reinforcement rings are added to brazed airfoil segments, then strength is improved, but device complexity worsens due to additional components and assembly steps
Solution Approach 1:
The reinforcement rings are integrated with the airfoil segments through brazing, merging structural reinforcement functionality with the existing segmented architecture. This combination approach strengthens the structure without requiring entirely separate reinforcement systems.
Solution Approach 2:
The reinforcement rings serve multiple functions including structural strengthening, sealing enhancement, and potential thermal management. This multi-functionality justifies the added complexity by consolidating multiple requirements into single components.
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
The solution effectively minimizes segment leakage and non-uniform deflections, providing robust joint strength and sealing while reducing manufacturing costs through the use of brazed airfoil segments and reinforcement rings tailored for thermal expansion matching.
Implementation Method 1
A static structure comprising multiple airfoil segments brazed together to form an annular core flow, with structural reinforcement rings mounted on the airfoil segments
Data Source
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AI summary
A static structure of a gas turbine engine includes a multiple of airfoil segments and at least one structural reinforcement ring mounted to the multiple of airfoil segments.