US20110002790A1 - Thermoplastic last-stage blade - Google Patents
Thermoplastic last-stage blade Download PDFInfo
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- US20110002790A1 US20110002790A1 US12/847,126 US84712610A US2011002790A1 US 20110002790 A1 US20110002790 A1 US 20110002790A1 US 84712610 A US84712610 A US 84712610A US 2011002790 A1 US2011002790 A1 US 2011002790A1
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- Prior art keywords
- turbine blade
- damping
- fiber
- blade
- turbine
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
- F01D—NON-POSITIVE DISPLACEMENT MACHINES OR ENGINES, e.g. STEAM TURBINES
- F01D5/00—Blades; Blade-carrying members; Heating, heat-insulating, cooling or antivibration means on the blades or the members
- F01D5/12—Blades
- F01D5/28—Selecting particular materials; Particular measures relating thereto; Measures against erosion or corrosion
- F01D5/282—Selecting composite materials, e.g. blades with reinforcing filaments
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F05—INDEXING SCHEMES RELATING TO ENGINES OR PUMPS IN VARIOUS SUBCLASSES OF CLASSES F01-F04
- F05D—INDEXING SCHEME FOR ASPECTS RELATING TO NON-POSITIVE-DISPLACEMENT MACHINES OR ENGINES, GAS-TURBINES OR JET-PROPULSION PLANTS
- F05D2300/00—Materials; Properties thereof
- F05D2300/40—Organic materials
- F05D2300/43—Synthetic polymers, e.g. plastics; Rubber
- F05D2300/436—Polyetherketones, e.g. PEEK
Definitions
- the present invention relates to a turbine blade.
- the present invention also relates to a turbine, in particular a steam turbine.
- the present invention further relates to a method for manufacturing a turbine blade.
- Turbine rotor blades made of steel are predominantly used nowadays in turbines, in particular in steam turbines.
- the achievable rotational speeds for rotor blades made of steel are limited due to the high dead weight.
- using rotor blades consisting of fiber-reinforced composite materials would be conceivable in order to reduce the mass of the blades significantly, which in turn enables the rotational speed to be increased.
- the object is achieved by means of a turbine blade, a turbine, in particular a steam turbine, and a method for manufacturing a turbine blade having the features recited in the independent claims.
- a turbine blade wherein sub-regions of the turbine blade or the entire turbine blade constitute or have a damping zone consisting of a damping layer.
- the damping layer has a fiber matrix system.
- the fiber matrix system has a thermoplastic matrix, in which matrix reinforcing fibers are embedded.
- a turbine which has the above-described turbine blade.
- a method for manufacturing a turbine blade is provided.
- reinforcing fibers are initially embedded into a thermoplastic matrix in order to form a fiber matrix system of a damping layer.
- a damping zone of the turbine blade is formed.
- the damping zone can embody sub-regions of the turbine blade or the entire turbine blade.
- damping zone an area of a turbine blade is described in which damping characteristics of the turbine blade are integrated.
- the damping zone is installed in particular in such regions of the turbine blade in which mostly higher shearing or moment loads occur than in the remaining regions of the turbine blade, with the result that damping is desirable in said damping zones.
- greater vibrations can be damped in the damping zone than in the remaining regions of the turbine blade.
- the damping zone can define a specific section along the extension zone or, as the case may be, along the length of a turbine blade.
- the damping zone can also define a specific region in a cross-section of the turbine blade.
- an outer region of a turbine blade can have a damping zone, while an inner region can define an arbitrary blade region.
- the entire turbine blade forms the damping zone. This means that the entire turbine blade can be manufactured from a plurality of damping layers and consequently can consist of the damping layers themselves.
- a “layer”, in particular a damping layer and/or a fiber layer, is understood to mean a stratum of a damping layer or, as the case may be, of a damping material and a stratum of a fiber layer or, as the case may be, of a reinforcing fiber layer.
- a layer can have a thickness of, for example, 0.1-1 mm, in particular a thickness of 0.2 mm, 0.25 mm and/or 0.3 mm, for example.
- fiber matrix system can be understood to mean a fiber composite consisting of a matrix and reinforcing fibers.
- the fiber matrix system can constitute, for example, the damping layer in its entirety or a part thereof.
- reinforcing fibers is understood to means fibers which can pass on and transfer forces that act on the fiber matrix system. In comparison with the matrix the fibers can exhibit a high rigidity, in particular in respect of tension. The force flow is mostly configured along the fiber in order to exploit the best rigidity characteristics of a reinforcing fiber.
- matrix is understood to mean a raw material which embeds the reinforcing fibers.
- the term “embed” serves to define that the reinforcing fibers are present spatially fixed in the matrix and consequently can enable load to be introduced and load to be directed out.
- the matrix can also protect the reinforcing fibers, for example, against compression in the event of pressure parallel to the fibers.
- the reinforcing fibers and the matrix are, for example, glued or, as the case may be, fused to one another so that load can be transferred between the matrix and the reinforcing fiber, whereby shearing forces can also be transferred.
- thermoplastic matrix serves to define the material of the matrix.
- a thermoplastic material or, as the case may be, a thermoplastic matrix has in particular damping characteristics.
- the thermoplastic material of the matrix has a lower rigidity and a higher damping value in relation to a reinforcing fiber that is subject to tension. Accordingly, the thermoplastic matrix can have a damping effect, whereas the reinforcing fiber has a stiffening effect.
- the thermoplastic matrix can also be reshaped or fused subsequently.
- the thermoplastic matrix can consist, for example, of polyetheretherketone (PEEK), of polyamide (PA), of polypropylene (PP), of polycarbonate (PC) or of polyethylene (PE).
- the reinforcing fibers can consist, for example, of synthetic fibers, such as e.g. carbon fibers, aramid fibers, polyester fibers, polyamide fibers or polyethylene fibers.
- synthetic fibers such as e.g. carbon fibers, aramid fibers, polyester fibers, polyamide fibers or polyethylene fibers.
- organic reinforcing fibers such as glass fibers, natural fibers or metallic fibers can equally well be used.
- a turbine blade which consists in particular of fiber composite materials can be selectively damped without the turbine blade's stability or rigidity being reduced to such an extent that an instability is created.
- a thermoplastic matrix material a selectively adjustable, advantageous potential for vibration damping can be achieved by means of the material itself.
- the material-side vibration damping is improved through the use of a material combination consisting of thermoplastic and reinforcing fiber in the critical damping zones or in the entire turbine blade.
- different combinations of different thermoplastic fiber matrix systems can be provided for damping zones subject to different loads in order to adapt the turbine blade in a targeted manner to a predefined load.
- the turbine blade can be subject to a subsequent reshaping of the profile of the turbine blade, this being achieved by reheating and consequently partly fusing or, as the case may be, melting the thermoplastic fiber matrix system.
- a targeted subsequent deformation or, as the case may be, readjustment or fine adjustment to suit specific turbine blade profiles or to match different load stresses is possible.
- a targeted detuning or, as the case may be, deformation of individual blades on the blade ring can be achieved in this way.
- the damping zone has fiber layers, the fiber layers and the damping layer forming a laminar structure.
- laminar structure is understood to mean, for example, a laminate which describes a stacking of the different layers, in particular the damping layers and the fiber layers, on top of one another.
- a laminar structure describes a layer-by-layer fabrication or, as the case may be, the layer-by-layer construction of the damping zone or also other regions of the turbine blade, such as the other blade regions, for example.
- the laminar structure or, as the case may be, the laminar structure materials consists or consist of layers superimposed on one another or, as the case may be, different numbers of layers.
- the individual strata or, as the case may be, the individual layers can be glued, for example, or they can mutually interlock due to the open-cell nature of the materials.
- the laminar structure can be immersed in resin in order to bond the layers to one another.
- the laminar structure forms the integral configuration of a component such that forces that act on the component can be transferred via the laminar structure.
- the laminar structure additionally has the homogeneously running surface of the component. In other words, fixtures glued onto the surface of a component externally do not count as part of the laminar structure of the component or, as the case may be, of the turbine blade.
- fiber layer describes a layer consisting of fibers that can have no thermoplastic material.
- the fiber layers can, for example, exhibit a high rigidity or, as the case may be, a higher rigidity than the damping layers and consist of different reinforcing fiber materials, as described above.
- the turbine blade has a blade region, the blade region consisting of a plurality of further fiber layers.
- the plurality of further fiber layers embodies a further laminar structure.
- the blade region or, as the case may be, the blade regions can adjoin the damping zone or zones of the turbine blade.
- the blade regions can consist of the plurality of further fiber layers that exhibit a higher rigidity and load-bearing capability by comparison with the damping zone. Vibrations can be transmitted, for example, from the blade region onto the damping zone, the damping zone being able to damp or, as the case may be, absorb the vibrations by means of the thermoplastic fiber matrix system.
- a turbine blade can be provided which along its extension direction has, for example, a plurality of blade regions which in turn adjoin a plurality of damping zones.
- the damping zones can be arranged at predefined regions having a high loading or, as the case may be, having a high damping requirement.
- the blade regions can be arranged at areas at which vibration are non-critical or, as the case may be, at which a high rigidity is required.
- a turbine blade can be individually adapted to suit the loads to which it is subject and consequently tailored to a detailed requirements profile in terms of costs and efficiency.
- the reinforcing fibers are embedded into the matrix at an angle of between 1° (degree) and 90° (degrees) to one another. More particularly with complex loads or, as the case may be, load directions, individual reinforcing fibers can be arranged at different angles to one another.
- the damping layer or the fiber layer can be produced, for example, as a woven fabric, as a knitted fabric or as a mesh having oriented reinforcing fibers.
- the turbine blade can be adapted to predefined load directions, with the result that the turbine blade can be selectively matched to a predefined requirements potential.
- the reinforcing fibers are embedded into the thermoplastic matrix parallel to one another.
- reinforcing fibers arranged in parallel can suffice. Complex interweaves and alignments of reinforcing fibers are then unnecessary, so that a manufacturing method having low manufacturing costs can be created in these areas with parallel reinforcing fibers.
- At least one of the reinforcing fibers has a hybrid yarn.
- the hybrid yarn has a thermoplastic material and a carbon fiber material.
- Such a hybrid yarn can consist, for example, of many yarns which are twisted together with one another or interlaced with one another and which together form the hybrid yarn.
- One part of said yarns can consist of a thermoplastic material and the other of a reinforcing fiber material, such as e.g. carbon fibers.
- the hybrid yarn in such a way that the thermoplastic material is embodied as yarn and the fiber yarn is fused into the thermoplastic yarn. In this way a targeted damping of the turbine blade can be provided in a simple manner already by means of the use of the thermoplastic yarn as a reinforcing fiber.
- the damping layer has a lower elastic rigidity and/or a higher damping value than the fiber layer.
- damping value describes the damping characteristics of a material.
- the damping value ‘tan ⁇ ’ can lie between 0 and 1, for example.
- the teen “rigidity” can describe the E modulus or G modulus, for example.
- a fiber can have a rigidity of 130 GPa in the longitudinal direction and only 8 GPa along the transverse direction.
- rigidities of 65 GPa for example, can be achieved in each main fiber direction.
- Each main fiber direction is aligned at an angle a relative to each other.
- the thermoplastic matrix can have a rigidity of 0.5 to 10 GPa, for example, yet in return exhibit better damping characteristics than the reinforcing fibers.
- the damping zone has a lower elastic rigidity and/or a higher damping value than the blade region.
- the turbine blade has an enveloping layer.
- the enveloping layer is wrapped around a surface or, as the case may be, a surface region of the turbine blade in such a way that the turbine blade is protected against external influences.
- the enveloping layer has a non-reinforced thermoplastic material which is identical to the matrix material. Owing to the high damping effect of a non-reinforced thermoplastic material the softness or, as the case may be, the elasticity of the thermoplastic material can be greater than the elasticity of the fiber layer.
- a surface made of thermoplastic material erodes less than, for example, a fiber layer consisting of reinforcing fibers having a higher rigidity. Accordingly, the service life of a turbine blade can be increased, since damage due to impingement of external particles is reduced.
- a thermoplastic material is generally more resistant to humidity than a reinforcing fiber, so corrosion is reduced.
- the damping zone has a further fiber matrix system having a thermoplastic matrix.
- the further fiber matrix system is disposed in the damping zone and/or in the blade region such that said system is exposed to external influences of the turbine blade.
- the further fiber matrix system having a thermoplastic matrix has reinforcing fibers which are present as fiber mats in arbitrary main fiber directions. As a result of the arbitrary alignment of the main fiber directions of the reinforcing fibers, the rigidity characteristic of the further fiber matrix system is reduced and a better absorption characteristic and a greater resistance toward an impact of external particles are achieved.
- the further fiber matrix system can also be extended over the other areas of the turbine blade, for example also over the blade regions.
- the further fiber matrix system having a fiber-reinforced matrix can have not only a high absorption capability in respect of impinging particles but also a higher rigidity, with the result that the further thermoplastic fiber matrix system can likewise contribute toward the overall rigidity of the turbine blade. Accordingly, a rigid material can be provided for a turbine blade while at the same time increasing the erosion resistance and also the corrosion resistance toward liquids of a surface of the turbine blade. With steam turbines in particular, erosion due to water droplets is critical.
- a surface or, as the case may be, an outer layer of the turbine blade consisting of non-reinforced thermoplastic or, as the case may be, of a terminating layer consisting of thermoplastic matrix material or, as the case may be, of a terminating layer of the further thermoplastic fiber matrix system can provide an integrated erosion layer without the necessity of applying additional sealing layers.
- a turbine in particular a steam turbine, is equipped with the above-described turbine blades.
- Steam turbines in particular have large diameters, in particular in the first compressor stage and the last turbines stage.
- High centrifugal forces, bending moments and torsion forces act in particular in the case of blade wheels of a steam turbine having a large diameter.
- turbine blades consisting of a composite material can be employed even for steam turbines having large diameters.
- thermoplastic matrix is melted during the embedding process and the reinforcing fibers are pressed onto the matrix.
- an economical manufacture using the hot-press method can be provided in that the thermoplastic material present in the matrix is melted. Long infiltration and curing times as in the case of conventional fiber composite layers, for example, can be dispensed with.
- the damping zone is reshaped by means of a further fusing or melting of the thermoplastic matrix in order to match a predefined shape of the turbine blade.
- the definitive shaping of the turbine blade e.g. a twisting of the turbine blade
- the manufacturing process e.g. a hot-press process.
- a subsequent reshaping or, as the case may be, readjustment helps in the case of specific problems with an oscillation frequency.
- the damping zone can be subsequently reshaped or, as the case may be, fine-adjusted, for example, to a changed or, as the case may be, unanticipated oscillation frequency.
- the property of the remeltability of the fiber matrix system also permits a subsequent blade repair.
- an additional thermoplastic material can be applied in order to rectify damage to the fiber matrix system. Accordingly, the possibility of a repair is created.
- an additional thermoplastic can be applied locally in order to repair damage to the turbine blade.
- FIG. 1 shows a turbine blade having a damping zone according to an exemplary embodiment of the present invention
- FIG. 2 shows a plan view onto a fiber matrix system in a damping layer according to an exemplary embodiment variant of the present invention.
- FIG. 3 shows a schematic view of a fiber matrix system in a damping layer according to an exemplary embodiment variant of the invention.
- FIG. 1 shows an exemplary embodiment variant of the turbine blade 100 according to an exemplary embodiment of the present invention.
- the turbine blade 100 has a damping zone 101 having a damping layer 103 .
- the damping layer 103 has a fiber matrix system 200 (see FIG. 2 ).
- the fiber matrix system 200 has a thermoplastic matrix 201 (see FIG. 2 ), in which thermoplastic matrix 201 reinforcing fibers 202 (see FIG. 2 ) are embedded.
- the turbine blade 100 has, as shown in FIG. 1 , two blade regions 102 which surround the damping zone 101 .
- the blade region 102 is formed, for example, from a further laminar structure 107 which can consist of a plurality of further fiber layers 105 . If the further fiber layers 105 consist, for example, of reinforcing fibers 202 consisting of carbon fibers or other stiffening composite fibers, the further laminar structure 107 embodies an extremely rigid blade region 102 .
- the fiber layers 104 in the damping zone 101 can transition seamlessly into the blade regions 102 .
- the fiber layers 104 together with the further fiber layers 105 form a continuously running layer.
- the damping zones 101 can be manufactured as semifinished products, wherein the fiber layers 104 do not run beyond the damping zone 101 or, as the case may be, do not protrude into the blade regions 102 .
- the fiber layers 104 are truncated, for example, at the border regions of the damping zones 101 .
- the vibration damping can be produced in that a laminar structure 106 forms the damping zone 101 , the laminar structure 106 consisting of at least one damping layer 103 and of further fiber layers 104 . Owing to the layer-by-layer structure by means of the damping layer 103 the damping zone 101 can be less rigid than the blade regions 102 , with the result that in this case vibration damping is produced by means of the laminar structure 106 , i.e. by means of the material itself
- an enveloping layer 108 can be molded around the turbine blade 100 , the enveloping layer 108 protecting at least the damping zone 101 but also in addition the blade regions 102 against external influences.
- the enveloping layer 108 can consist, for example, of a non-reinforced thermoplastic material.
- a non-reinforced thermoplastic material can embody a soft enveloping layer 108 such that impacts of foreign particles onto the turbine blade are cushioned and can rebound by virtue of the soft enveloping layer 108 .
- thermoplastic enveloping layer 108 As a result of the low rigidity of the thermoplastic enveloping layer 108 , the impact of a foreign particle causes the enveloping layer 108 to deform slightly such that the impact energy is absorbed without this resulting in fissures or other forms of damage being produced.
- the damping zone 101 or in addition also the blade regions 102 can have a further thermoplastic fiber matrix system 109 which can protect the turbine blade 100 against external influences.
- the further fiber matrix system 109 can have a thermoplastic matrix 201 into which reinforcing fibers 202 are embedded. If the reinforcing fibers 202 are arbitrarily present in the thermoplastic matrix 201 , this can be referred to as a fiber mat.
- the fiber mats have a lower rigidity than fiber matrix systems with directed composite fibers, with the result that in turn a greater softness or, as the case may be, elasticity can be created with the further fiber matrix system 109 . This leads in turn to a protection against external impacts of foreign particles and against erosion of the surface of the turbine blade 100 .
- FIG. 2 shows a fiber matrix system 200 which consists of a thermoplastic matrix 201 .
- Reinforcing fibers 202 are embedded into the thermoplastic matrix 201 .
- the reinforcing fibers 202 can be aligned in parallel. Accordingly the reinforcing fibers, which are subject to tension, can provide a high degree of stiffness of the fiber matrix system 200 . High damping characteristics are possible transversely to the fiber direction of the reinforcing fibers 202 owing to the low rigidity of the reinforcing fibers 202 .
- FIG. 3 shows a further exemplary embodiment variant of a fiber matrix system 200 , in which reinforcing fibers 202 are embedded into a thermoplastic matrix 201 .
- the reinforcing fibers 200 are in this case embedded at a specific angle a between further reinforcing fibers 201 .
- the reinforcing fibers 201 are not present parallel to one another.
- the damping characteristics are in this case primarily produced by means of the thermoplastic matrix 201 .
- a damping zone 101 can be provided which can have reinforcing properties or, as the case may be, rigidity properties on the one hand and damping characteristics on the other.
Abstract
Description
- This application claims priority of German Patent Application No. 10 2009 036 018.2 DE filed Aug. 4, 2009, which is incorporated by reference herein in its entirety.
- The present invention relates to a turbine blade. The present invention also relates to a turbine, in particular a steam turbine. The present invention further relates to a method for manufacturing a turbine blade.
- Turbine rotor blades made of steel are predominantly used nowadays in turbines, in particular in steam turbines. In particular in large stationary steam turbines having large diameters, the achievable rotational speeds for rotor blades made of steel are limited due to the high dead weight. In this case using rotor blades consisting of fiber-reinforced composite materials would be conceivable in order to reduce the mass of the blades significantly, which in turn enables the rotational speed to be increased.
- Furthermore, in stationary steam turbines that have large diameters and consequently large blade lengths, undesirable vibrations occur which have to be damped. In present-day applications, therefore, vibration damping is produced by way of additional damping wires or shrouding bands on the surface of the blades. Owing to the blade geometry it is often extremely labor-intensive, time-consuming and difficult to apply said damping wires or shrouding bands to the blades, which in turn entails a deterioration in efficiency and necessitates a complex manufacturing overhead.
- It is an object of the present invention to provide a turbine blade having damping characteristics.
- The object is achieved by means of a turbine blade, a turbine, in particular a steam turbine, and a method for manufacturing a turbine blade having the features recited in the independent claims.
- According to a first exemplary embodiment variant, a turbine blade is provided wherein sub-regions of the turbine blade or the entire turbine blade constitute or have a damping zone consisting of a damping layer. The damping layer has a fiber matrix system. The fiber matrix system has a thermoplastic matrix, in which matrix reinforcing fibers are embedded.
- According to a further exemplary embodiment variant, a turbine is provided which has the above-described turbine blade.
- According to a further exemplary embodiment variant, a method for manufacturing a turbine blade is provided. According to the method, reinforcing fibers are initially embedded into a thermoplastic matrix in order to form a fiber matrix system of a damping layer. By means of the damping layer a damping zone of the turbine blade is formed. The damping zone can embody sub-regions of the turbine blade or the entire turbine blade.
- By means of the term “damping zone” an area of a turbine blade is described in which damping characteristics of the turbine blade are integrated. The damping zone is installed in particular in such regions of the turbine blade in which mostly higher shearing or moment loads occur than in the remaining regions of the turbine blade, with the result that damping is desirable in said damping zones. Furthermore, greater vibrations can be damped in the damping zone than in the remaining regions of the turbine blade. The damping zone can define a specific section along the extension zone or, as the case may be, along the length of a turbine blade. The damping zone can also define a specific region in a cross-section of the turbine blade. Thus, for example, an outer region of a turbine blade can have a damping zone, while an inner region can define an arbitrary blade region. In the damping zone it is possible, for example, for high centrifugal forces, high bending loads, high shearing stresses, high torsional loads or undesirable vibrations to be applied which require damping and are damped in the damping zone. For a turbine blade, in particular a thermoplastic last-stage blade, the entire turbine blade forms the damping zone. This means that the entire turbine blade can be manufactured from a plurality of damping layers and consequently can consist of the damping layers themselves.
- A “layer”, in particular a damping layer and/or a fiber layer, is understood to mean a stratum of a damping layer or, as the case may be, of a damping material and a stratum of a fiber layer or, as the case may be, of a reinforcing fiber layer. A layer can have a thickness of, for example, 0.1-1 mm, in particular a thickness of 0.2 mm, 0.25 mm and/or 0.3 mm, for example.
- The term “fiber matrix system” can be understood to mean a fiber composite consisting of a matrix and reinforcing fibers. The fiber matrix system can constitute, for example, the damping layer in its entirety or a part thereof.
- The term “reinforcing fibers” is understood to means fibers which can pass on and transfer forces that act on the fiber matrix system. In comparison with the matrix the fibers can exhibit a high rigidity, in particular in respect of tension. The force flow is mostly configured along the fiber in order to exploit the best rigidity characteristics of a reinforcing fiber.
- The term “matrix” is understood to mean a raw material which embeds the reinforcing fibers. The term “embed” serves to define that the reinforcing fibers are present spatially fixed in the matrix and consequently can enable load to be introduced and load to be directed out. The matrix can also protect the reinforcing fibers, for example, against compression in the event of pressure parallel to the fibers. The reinforcing fibers and the matrix are, for example, glued or, as the case may be, fused to one another so that load can be transferred between the matrix and the reinforcing fiber, whereby shearing forces can also be transferred.
- The term “thermoplastic” matrix serves to define the material of the matrix. A thermoplastic material or, as the case may be, a thermoplastic matrix has in particular damping characteristics. The thermoplastic material of the matrix has a lower rigidity and a higher damping value in relation to a reinforcing fiber that is subject to tension. Accordingly, the thermoplastic matrix can have a damping effect, whereas the reinforcing fiber has a stiffening effect. The thermoplastic matrix can also be reshaped or fused subsequently. The thermoplastic matrix can consist, for example, of polyetheretherketone (PEEK), of polyamide (PA), of polypropylene (PP), of polycarbonate (PC) or of polyethylene (PE).
- The reinforcing fibers can consist, for example, of synthetic fibers, such as e.g. carbon fibers, aramid fibers, polyester fibers, polyamide fibers or polyethylene fibers. As well as these organic reinforcing fibers, inorganic fibers such as glass fibers, natural fibers or metallic fibers can equally well be used.
- By means of the present invention a turbine blade which consists in particular of fiber composite materials can be selectively damped without the turbine blade's stability or rigidity being reduced to such an extent that an instability is created. Through the use of a thermoplastic matrix material a selectively adjustable, advantageous potential for vibration damping can be achieved by means of the material itself. In other words, the material-side vibration damping is improved through the use of a material combination consisting of thermoplastic and reinforcing fiber in the critical damping zones or in the entire turbine blade. Furthermore, different combinations of different thermoplastic fiber matrix systems can be provided for damping zones subject to different loads in order to adapt the turbine blade in a targeted manner to a predefined load.
- Furthermore, owing to the use of the thermoplastic fiber matrix system the turbine blade can be subject to a subsequent reshaping of the profile of the turbine blade, this being achieved by reheating and consequently partly fusing or, as the case may be, melting the thermoplastic fiber matrix system. In this way a targeted subsequent deformation or, as the case may be, readjustment or fine adjustment to suit specific turbine blade profiles or to match different load stresses is possible. A targeted detuning or, as the case may be, deformation of individual blades on the blade ring can be achieved in this way.
- According to a further exemplary embodiment variant, the damping zone has fiber layers, the fiber layers and the damping layer forming a laminar structure.
- The term “laminar structure” is understood to mean, for example, a laminate which describes a stacking of the different layers, in particular the damping layers and the fiber layers, on top of one another. A laminar structure describes a layer-by-layer fabrication or, as the case may be, the layer-by-layer construction of the damping zone or also other regions of the turbine blade, such as the other blade regions, for example. The laminar structure or, as the case may be, the laminar structure materials consists or consist of layers superimposed on one another or, as the case may be, different numbers of layers. The individual strata or, as the case may be, the individual layers can be glued, for example, or they can mutually interlock due to the open-cell nature of the materials. For example, the laminar structure can be immersed in resin in order to bond the layers to one another. The laminar structure forms the integral configuration of a component such that forces that act on the component can be transferred via the laminar structure. The laminar structure additionally has the homogeneously running surface of the component. In other words, fixtures glued onto the surface of a component externally do not count as part of the laminar structure of the component or, as the case may be, of the turbine blade.
- In this context the term “fiber layer” describes a layer consisting of fibers that can have no thermoplastic material. The fiber layers can, for example, exhibit a high rigidity or, as the case may be, a higher rigidity than the damping layers and consist of different reinforcing fiber materials, as described above.
- According to another exemplary embodiment variant, the turbine blade has a blade region, the blade region consisting of a plurality of further fiber layers. The plurality of further fiber layers embodies a further laminar structure. The blade region or, as the case may be, the blade regions can adjoin the damping zone or zones of the turbine blade. The blade regions can consist of the plurality of further fiber layers that exhibit a higher rigidity and load-bearing capability by comparison with the damping zone. Vibrations can be transmitted, for example, from the blade region onto the damping zone, the damping zone being able to damp or, as the case may be, absorb the vibrations by means of the thermoplastic fiber matrix system. By means of the present exemplary embodiment a turbine blade can be provided which along its extension direction has, for example, a plurality of blade regions which in turn adjoin a plurality of damping zones. The damping zones can be arranged at predefined regions having a high loading or, as the case may be, having a high damping requirement. The blade regions can be arranged at areas at which vibration are non-critical or, as the case may be, at which a high rigidity is required. Thus, a turbine blade can be individually adapted to suit the loads to which it is subject and consequently tailored to a detailed requirements profile in terms of costs and efficiency.
- According to a further exemplary embodiment variant, the reinforcing fibers are embedded into the matrix at an angle of between 1° (degree) and 90° (degrees) to one another. More particularly with complex loads or, as the case may be, load directions, individual reinforcing fibers can be arranged at different angles to one another. In this case the damping layer or the fiber layer can be produced, for example, as a woven fabric, as a knitted fabric or as a mesh having oriented reinforcing fibers. Depending on the alignment of the reinforcing fibers, the turbine blade can be adapted to predefined load directions, with the result that the turbine blade can be selectively matched to a predefined requirements potential.
- According to another exemplary embodiment variant, the reinforcing fibers are embedded into the thermoplastic matrix parallel to one another. In areas in which the turbine blade is subject exclusively to tension, for example, reinforcing fibers arranged in parallel can suffice. Complex interweaves and alignments of reinforcing fibers are then unnecessary, so that a manufacturing method having low manufacturing costs can be created in these areas with parallel reinforcing fibers.
- According to a further exemplary embodiment variant, at least one of the reinforcing fibers has a hybrid yarn. The hybrid yarn has a thermoplastic material and a carbon fiber material. Such a hybrid yarn can consist, for example, of many yarns which are twisted together with one another or interlaced with one another and which together form the hybrid yarn. One part of said yarns can consist of a thermoplastic material and the other of a reinforcing fiber material, such as e.g. carbon fibers. Furthermore it is also possible to form the hybrid yarn in such a way that the thermoplastic material is embodied as yarn and the fiber yarn is fused into the thermoplastic yarn. In this way a targeted damping of the turbine blade can be provided in a simple manner already by means of the use of the thermoplastic yarn as a reinforcing fiber.
- According to another exemplary embodiment variant, the damping layer has a lower elastic rigidity and/or a higher damping value than the fiber layer.
- The term “damping value” describes the damping characteristics of a material. The damping value ‘tan δ’ can lie between 0 and 1, for example.
- The teen “rigidity” can describe the E modulus or G modulus, for example. Thus, for example, a fiber can have a rigidity of 130 GPa in the longitudinal direction and only 8 GPa along the transverse direction. In the case of a weft of fibers, rigidities of 65 GPa, for example, can be achieved in each main fiber direction. Each main fiber direction is aligned at an angle a relative to each other. The thermoplastic matrix can have a rigidity of 0.5 to 10 GPa, for example, yet in return exhibit better damping characteristics than the reinforcing fibers.
- According to a further exemplary embodiment variant, the damping zone has a lower elastic rigidity and/or a higher damping value than the blade region.
- According to a further exemplary embodiment variant, the turbine blade has an enveloping layer. The enveloping layer is wrapped around a surface or, as the case may be, a surface region of the turbine blade in such a way that the turbine blade is protected against external influences. The enveloping layer has a non-reinforced thermoplastic material which is identical to the matrix material. Owing to the high damping effect of a non-reinforced thermoplastic material the softness or, as the case may be, the elasticity of the thermoplastic material can be greater than the elasticity of the fiber layer. When external particles strike the surface of the turbine blade, a surface made of thermoplastic material erodes less than, for example, a fiber layer consisting of reinforcing fibers having a higher rigidity. Accordingly, the service life of a turbine blade can be increased, since damage due to impingement of external particles is reduced. Moreover, a thermoplastic material is generally more resistant to humidity than a reinforcing fiber, so corrosion is reduced.
- According to another exemplary embodiment variant, the damping zone has a further fiber matrix system having a thermoplastic matrix. The further fiber matrix system is disposed in the damping zone and/or in the blade region such that said system is exposed to external influences of the turbine blade. The further fiber matrix system having a thermoplastic matrix has reinforcing fibers which are present as fiber mats in arbitrary main fiber directions. As a result of the arbitrary alignment of the main fiber directions of the reinforcing fibers, the rigidity characteristic of the further fiber matrix system is reduced and a better absorption characteristic and a greater resistance toward an impact of external particles are achieved. Moreover, the further fiber matrix system can also be extended over the other areas of the turbine blade, for example also over the blade regions. In comparison with a non-reinforced thermoplastic matrix, the further fiber matrix system having a fiber-reinforced matrix can have not only a high absorption capability in respect of impinging particles but also a higher rigidity, with the result that the further thermoplastic fiber matrix system can likewise contribute toward the overall rigidity of the turbine blade. Accordingly, a rigid material can be provided for a turbine blade while at the same time increasing the erosion resistance and also the corrosion resistance toward liquids of a surface of the turbine blade. With steam turbines in particular, erosion due to water droplets is critical. A surface or, as the case may be, an outer layer of the turbine blade consisting of non-reinforced thermoplastic or, as the case may be, of a terminating layer consisting of thermoplastic matrix material or, as the case may be, of a terminating layer of the further thermoplastic fiber matrix system can provide an integrated erosion layer without the necessity of applying additional sealing layers.
- According to a further exemplary embodiment variant, a turbine, in particular a steam turbine, is equipped with the above-described turbine blades. Steam turbines in particular have large diameters, in particular in the first compressor stage and the last turbines stage. High centrifugal forces, bending moments and torsion forces act in particular in the case of blade wheels of a steam turbine having a large diameter. Specifically in that situation it is suitable to use the turbine blade according to the invention in order to achieve adequate rigidity while improving damping characteristics compared to conventional turbine blades. Accordingly, turbine blades consisting of a composite material can be employed even for steam turbines having large diameters.
- According to a further exemplary embodiment variant of the method, the thermoplastic matrix is melted during the embedding process and the reinforcing fibers are pressed onto the matrix. Thus, an economical manufacture using the hot-press method can be provided in that the thermoplastic material present in the matrix is melted. Long infiltration and curing times as in the case of conventional fiber composite layers, for example, can be dispensed with.
- According to a further exemplary embodiment variant of the method, the damping zone is reshaped by means of a further fusing or melting of the thermoplastic matrix in order to match a predefined shape of the turbine blade. Owing to this fusibility or meltability of the fiber matrix system or, as the case may be, of the thermoplastic matrix the definitive shaping of the turbine blade, e.g. a twisting of the turbine blade, can be carried out directly after the manufacturing process, e.g. a hot-press process. This can be useful above all in the case of special turbine requirements, in particular in the case of special requirements in terms of the twisting angle, etc. Furthermore, a subsequent reshaping or, as the case may be, readjustment helps in the case of specific problems with an oscillation frequency. By means of the remelting the damping zone can be subsequently reshaped or, as the case may be, fine-adjusted, for example, to a changed or, as the case may be, unanticipated oscillation frequency.
- Furthermore, the property of the remeltability of the fiber matrix system also permits a subsequent blade repair. For example, an additional thermoplastic material can be applied in order to rectify damage to the fiber matrix system. Accordingly, the possibility of a repair is created. In other words, an additional thermoplastic can be applied locally in order to repair damage to the turbine blade.
- It is pointed out that embodiment variants of the invention have been described with reference to different subject matters of the invention. In particular some embodiment variants of the invention are described by means of device-related claims and other embodiment variants of the invention by means of method-related claims. However, it will become immediately clear to the person skilled in the art when reading this application that, unless explicitly stated otherwise, in addition to a combination of features that belong to one type of inventive subject matter, an arbitrary combination of features that belong to different types of inventive subject matter is also possible.
- Further advantages and features of the present invention will emerge from the following exemplary description of currently preferred embodiments.
-
FIG. 1 shows a turbine blade having a damping zone according to an exemplary embodiment of the present invention; -
FIG. 2 shows a plan view onto a fiber matrix system in a damping layer according to an exemplary embodiment variant of the present invention; and -
FIG. 3 shows a schematic view of a fiber matrix system in a damping layer according to an exemplary embodiment variant of the invention. - The same or similar components are labeled with the same reference numerals throughout the figures. The depiction in the figures is schematic and not to scale.
-
FIG. 1 shows an exemplary embodiment variant of theturbine blade 100 according to an exemplary embodiment of the present invention. Theturbine blade 100 has a dampingzone 101 having a dampinglayer 103. The dampinglayer 103 has a fiber matrix system 200 (seeFIG. 2 ). Thefiber matrix system 200 has a thermoplastic matrix 201 (seeFIG. 2 ), in whichthermoplastic matrix 201 reinforcing fibers 202 (seeFIG. 2 ) are embedded. - The
turbine blade 100 has, as shown inFIG. 1 , twoblade regions 102 which surround the dampingzone 101. Theblade region 102 is formed, for example, from a furtherlaminar structure 107 which can consist of a plurality of further fiber layers 105. If thefurther fiber layers 105 consist, for example, of reinforcingfibers 202 consisting of carbon fibers or other stiffening composite fibers, the furtherlaminar structure 107 embodies an extremelyrigid blade region 102. - The fiber layers 104 in the damping
zone 101 can transition seamlessly into theblade regions 102. In the case of a seamless or, as the case may be, constant transition of the fiber layers 104 from the dampingzone 102 into theblade regions 102, the fiber layers 104 together with thefurther fiber layers 105 form a continuously running layer. Furthermore, the dampingzones 101 can be manufactured as semifinished products, wherein the fiber layers 104 do not run beyond the dampingzone 101 or, as the case may be, do not protrude into theblade regions 102. The fiber layers 104 are truncated, for example, at the border regions of the dampingzones 101. - In the damping
zone 101, the vibration damping can be produced in that alaminar structure 106 forms the dampingzone 101, thelaminar structure 106 consisting of at least one dampinglayer 103 and of further fiber layers 104. Owing to the layer-by-layer structure by means of the dampinglayer 103 the dampingzone 101 can be less rigid than theblade regions 102, with the result that in this case vibration damping is produced by means of thelaminar structure 106, i.e. by means of the material itself - Furthermore, an enveloping layer 108 can be molded around the
turbine blade 100, the enveloping layer 108 protecting at least the dampingzone 101 but also in addition theblade regions 102 against external influences. In this arrangement the enveloping layer 108 can consist, for example, of a non-reinforced thermoplastic material. A non-reinforced thermoplastic material can embody a soft enveloping layer 108 such that impacts of foreign particles onto the turbine blade are cushioned and can rebound by virtue of the soft enveloping layer 108. As a result of the low rigidity of the thermoplastic enveloping layer 108, the impact of a foreign particle causes the enveloping layer 108 to deform slightly such that the impact energy is absorbed without this resulting in fissures or other forms of damage being produced. - Furthermore, the damping
zone 101 or in addition also theblade regions 102 can have a further thermoplastic fiber matrix system 109 which can protect theturbine blade 100 against external influences. The further fiber matrix system 109 can have athermoplastic matrix 201 into which reinforcingfibers 202 are embedded. If the reinforcingfibers 202 are arbitrarily present in thethermoplastic matrix 201, this can be referred to as a fiber mat. The fiber mats have a lower rigidity than fiber matrix systems with directed composite fibers, with the result that in turn a greater softness or, as the case may be, elasticity can be created with the further fiber matrix system 109. This leads in turn to a protection against external impacts of foreign particles and against erosion of the surface of theturbine blade 100. -
FIG. 2 shows afiber matrix system 200 which consists of athermoplastic matrix 201. Reinforcingfibers 202 are embedded into thethermoplastic matrix 201. As shown inFIG. 2 , the reinforcingfibers 202 can be aligned in parallel. Accordingly the reinforcing fibers, which are subject to tension, can provide a high degree of stiffness of thefiber matrix system 200. High damping characteristics are possible transversely to the fiber direction of the reinforcingfibers 202 owing to the low rigidity of the reinforcingfibers 202. -
FIG. 3 shows a further exemplary embodiment variant of afiber matrix system 200, in which reinforcingfibers 202 are embedded into athermoplastic matrix 201. The reinforcingfibers 200 are in this case embedded at a specific angle a between further reinforcingfibers 201. In other words, the reinforcingfibers 201 are not present parallel to one another. By means of this multidirectional alignment of the reinforcing fibers 202 a high rigidity of the reinforcingfibers 202 in a plurality of predefined directions can be achieved in a targeted manner. The damping characteristics are in this case primarily produced by means of thethermoplastic matrix 201. This means that a dampingzone 101 can be provided which can have reinforcing properties or, as the case may be, rigidity properties on the one hand and damping characteristics on the other. - For completeness it should be pointed out that “comprising” excludes no other elements or steps and “one” or “a” does not exclude a plurality. Let it furthermore be pointed out that features or steps that have been described with reference to one of the above exemplary embodiments can also be used in combination with other features or steps of other above-described exemplary embodiments. Reference signs in the claims are not to be regarded as limiting.
Claims (20)
Applications Claiming Priority (2)
Application Number | Priority Date | Filing Date | Title |
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DE102009036018.2 | 2009-08-04 | ||
DE102009036018A DE102009036018A1 (en) | 2009-08-04 | 2009-08-04 | Thermoplastic final stage blade |
Publications (1)
Publication Number | Publication Date |
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US20110002790A1 true US20110002790A1 (en) | 2011-01-06 |
Family
ID=42537775
Family Applications (1)
Application Number | Title | Priority Date | Filing Date |
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US12/847,126 Abandoned US20110002790A1 (en) | 2009-04-08 | 2010-07-30 | Thermoplastic last-stage blade |
Country Status (5)
Country | Link |
---|---|
US (1) | US20110002790A1 (en) |
EP (1) | EP2287447B1 (en) |
JP (1) | JP2011033037A (en) |
CN (1) | CN101988394A (en) |
DE (1) | DE102009036018A1 (en) |
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US20150233830A1 (en) * | 2012-08-10 | 2015-08-20 | Hamamatsu Photonics K.K. | Surface-enhanced raman scattering unit |
JP2016512584A (en) * | 2013-02-22 | 2016-04-28 | ゼネラル・エレクトリック・カンパニイ | Hybrid turbine blade including multiple insert sections |
EP3406778A1 (en) * | 2017-05-22 | 2018-11-28 | Ratier-Figeac SAS | Method of manufacturing a composite aircraft blade |
US10746030B2 (en) | 2017-05-22 | 2020-08-18 | Ratier-Figeac Sas | Composite blade and method of manufacture |
WO2020182896A1 (en) * | 2019-03-11 | 2020-09-17 | Saint-Gobain Performance Plastics France | Method for the preparation of a polymeric material |
US20210394464A1 (en) * | 2018-11-07 | 2021-12-23 | Siemens Gamesa Renewable Energy Service Gmbh | A method and a system for manufacturing a fiber composite component of a wind energy installation |
US11420368B2 (en) | 2018-12-18 | 2022-08-23 | Saint-Gobain Performance Plastics France | Method for the preparation of composite material in sandwich form |
US20230358143A1 (en) * | 2020-09-11 | 2023-11-09 | Safran Aircraft Engines | Hybridization of the fibers of the fibrous reinforcement of a fan blade with elastic fibers |
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US9040138B2 (en) * | 2013-04-29 | 2015-05-26 | General Electric Company | Composite article including composite to metal interlock and method of fabrication |
ES2942884T3 (en) * | 2015-04-30 | 2023-06-07 | Ecp Entw Mbh | Rotor for a fluid pump |
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FR3090462B1 (en) * | 2018-12-21 | 2021-01-15 | Safran | Fiber-reinforced composite part with increased vibration resistance |
DE102020201867A1 (en) | 2020-02-14 | 2021-08-19 | Siemens Aktiengesellschaft | Fiber-reinforced rotor blade for a turbomachine and method for manufacturing such a rotor blade |
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Also Published As
Publication number | Publication date |
---|---|
JP2011033037A (en) | 2011-02-17 |
DE102009036018A1 (en) | 2011-02-17 |
CN101988394A (en) | 2011-03-23 |
EP2287447B1 (en) | 2018-11-07 |
EP2287447A2 (en) | 2011-02-23 |
EP2287447A3 (en) | 2013-07-17 |
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