Turbomachine Blade Fabrication via Segmented Preform Assembly
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Solution Overview
Problem
Current methods for manufacturing turbomachine blades made of composite materials face challenges in achieving complex shapes while maintaining mechanical and thermal properties, and are complex due to the need for three-dimensional weaving and the resulting mechanical property reduction from aerodynamic and piston effects.
Innovation Solution
A method involving the separate production and consolidation of fibrous preforms for the blade and platform, with a ceramic fiber strand interposed between them, allowing for simplified manufacturing and improved mechanical strength through co-densification, enabling the creation of turbomachine blades with enhanced mechanical and thermal properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If three-dimensional weaving is used to manufacture composite turbomachine blades, then the blades can achieve complex shapes, but the manufacturing process becomes complex and mechanical properties are reduced
Solution Approach 1:
The blade is divided into multiple separate preforms (blade preform, platform preforms, distributor preform) that are manufactured independently and then assembled. This segmentation allows each preform to be optimized for its specific function and shape requirements without the complexity of monobloc three-dimensional weaving, while maintaining the ability to achieve complex overall blade geometries through the assembly of these simpler components.
2Shape
If three-dimensional weaving is used to manufacture composite turbomachine blades, then the blades can achieve complex shapes, but mechanical properties are reduced due to aerodynamic and piston effects
Solution Approach 1:
By segmenting the blade into separate preforms that are consolidated rather than three-dimensionally woven, the structure avoids the mechanical property degradation associated with complex weaving patterns. The consolidation process creates strong inter-preform bonds while maintaining the mechanical integrity of each segment, resulting in improved overall mechanical strength compared to monobloc three-dimensional woven structures.
Solution Approach 2:
The invention uses composite material construction where multiple preforms made of ceramic fibers are consolidated together with a matrix material. This composite approach allows each preform to contribute its optimized mechanical properties while the matrix material provides additional strength and structural integrity, overcoming the mechanical property limitations of three-dimensional weaving.
3Ease of manufacture
If separate preforms are assembled and co-densified, then manufacturing is simplified and mechanical strength is enhanced, but additional consolidation steps are required
Solution Approach 1:
The invention combines multiple separate preforms into a single integrated blade structure through consolidation and co-densification processes. While this requires additional steps compared to monobloc weaving, the merging of independently optimized preforms results in a structurally superior product with enhanced mechanical properties and simplified manufacturing of individual components. The consolidation process integrates the separate preforms into a unified structure that would be difficult to achieve through other means.
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 simplifies the manufacturing process, enhances the mechanical strength of turbomachine blades, and allows for the creation of blades with complex geometries that can withstand increased gas temperatures and reduce cooling flow rates, improving propulsion system performance.
Implementation Method 1
a method for manufacturing a turbomachine blade made of composite material, in particular for an aeronautical engine, comprising: producing a first fiber preform comprising ceramic fibers, the first fiber preform forming a blade preform; producing a second fiber preform comprising ceramic fibers, the second fiber preform forming a platform preform; producing a strand of ceramic fibers; consolidating the first fiber preform in a single piece, the second fiber preform in a single piece and the strand of ceramic fibers to form a first consolidated preform, a second consolidated preform comprising a housing and a consolidated strand
Implementation Method 2
co-densification of the assembly to form the turbomachine blade
Data Source
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AI summary
The invention relates to a method (100) for fabricating a turbomachine engine blade made from a ceramic matrix composite material comprising a blade and a platform, producing (102) a first fibrous preform, the first fibrous preform forming a blade preform, producing (104) a second fibrous preform comprising a recess, the second fibrous preform forming a platform preform, producing (106) a strand of ceramic fibres, consolidating (108) the fibrous preforms and the strand of ceramic fibres to form consolidated preforms and a consolidated strand, assembling (110) the consolidated preforms by engagement and cooperation of the first consolidated preform in the recess, the consolidated strand being positioned between the first consolidated preform and the second consolidated preform, co-densifying the assembly in order to form the turbomachine blade.