Woven Composite Rotor Blade for Foreign Object Damage Resistance

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Solution Overview

Problem

In gas turbine engines, the composite material bonded to the surface of rotor blades can be liberated when struck by foreign objects, leading to damage, and the structural load path is often dominated by titanium rather than the composite, which reduces its effectiveness.

Innovation Solution

A rotor blade fabrication method involving a dovetail and airfoil with openings through which a composite material is woven, providing a smooth aerodynamic profile and ensuring the composite is securely attached to the metal surface, enhancing structural integrity and resistance to foreign object damage.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If composite material is bonded to the external surface of the airfoil, then the airfoil can be constructed with a metallic core providing structural support, but the composite material may be liberated from the airfoil upon impact with foreign objects causing further damage

Engineering Contradiction:

Improvestructural supportVSAvoidforeign object damage

Core Design Contradiction:

StrengthVSObject-affected harmful factors

Solution Approach 1:

The composite material is integrated into the airfoil structure by weaving it through openings in the metallic airfoil rather than merely bonding it to the external surface. This merging of composite and metallic materials creates a unified structure where the composite becomes an intrinsic part of the airfoil, preventing liberation upon impact while maintaining structural support functions.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The composite material is pre-positioned and woven through the openings in the metallic airfoil during the manufacturing process, before the airfoil is put into service. This preliminary integration ensures that the composite is securely embedded in the correct positions, creating a robust structure that resists foreign object damage from the outset.

Inventive Principle:

Principle #10Preliminary action

2Weight of moving object

If composite material is bonded to the surface of the airfoil, then weight reduction can be achieved, but the titanium dominates the structural load path reducing composite effectiveness

Engineering Contradiction:

Improveairfoil weightVSAvoidstructural load path

Core Design Contradiction:

Weight of moving objectVSStrength

Solution Approach 1:

The composite material is woven through the metallic airfoil structure, creating an integrated load-bearing system where both materials contribute to the structural load path. This merging allows the composite to actively participate in carrying structural loads rather than being a non-structural skin, optimizing the weight-strength balance.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The invention utilizes a composite structure combining metallic and composite materials in a woven configuration. This composite construction allows both materials to work together synergistically, with the composite material contributing to the structural load path while providing weight reduction benefits, rather than the titanium dominating the entire load path.

Inventive Principle:

Principle #40Composite materials

3Reliability

If composite material is woven through openings in the airfoil, then the composite is securely attached preventing liberation, but the manufacturing process becomes more complex

Engineering Contradiction:

Improvecomposite attachmentVSAvoidfabrication process

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The composite material is woven through the openings in the metallic airfoil during the manufacturing process, before the airfoil is put into service. This preliminary integration ensures that the composite is securely embedded in the correct positions, creating a robust structure that resists foreign object damage from the outset.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The composite material is nested within the metallic airfoil structure by weaving it through the openings. This nesting approach allows the composite to be securely positioned within the three-dimensional structure of the airfoil, creating a reliable attachment that prevents liberation while maintaining a relatively efficient manufacturing process.

Inventive Principle:

Principle #7Nested doll (Nesting)

Data Source

PatentUS7547194B2Rotor blade and method of fabricating the same

Publication Date: 2009.06.16 GENERAL ELECTRIC CO

AI summary

A method for fabricating a rotor blade includes fabricating a rotor blade that includes a dovetail and an airfoil coupled to the dovetail, the airfoil including a first side, a second side, and a plurality of openings extending therethrough, and weaving a composite material through the openings such that the airfoil has an aerodynamic profile that is substantially smooth from an airfoil leading edge to an airfoil trailing edge.