US20130224035A1 - Composite airfoil with local tailoring of material properties - Google Patents
Composite airfoil with local tailoring of material properties Download PDFInfo
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- US20130224035A1 US20130224035A1 US13/408,099 US201213408099A US2013224035A1 US 20130224035 A1 US20130224035 A1 US 20130224035A1 US 201213408099 A US201213408099 A US 201213408099A US 2013224035 A1 US2013224035 A1 US 2013224035A1
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- yarns
- preform
- matrix
- airfoil
- composite airfoil
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Classifications
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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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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29B—PREPARATION OR PRETREATMENT OF THE MATERIAL TO BE SHAPED; MAKING GRANULES OR PREFORMS; RECOVERY OF PLASTICS OR OTHER CONSTITUENTS OF WASTE MATERIAL CONTAINING PLASTICS
- B29B11/00—Making preforms
- B29B11/14—Making preforms characterised by structure or composition
- B29B11/16—Making preforms characterised by structure or composition comprising fillers or reinforcement
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
- B29C70/003—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts characterised by the matrix material, e.g. material composition or physical properties
- B29C70/0035—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts characterised by the matrix material, e.g. material composition or physical properties comprising two or more matrix materials
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
- B29C70/04—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising reinforcements only, e.g. self-reinforcing plastics
- B29C70/06—Fibrous reinforcements only
- B29C70/10—Fibrous reinforcements only characterised by the structure of fibrous reinforcements, e.g. hollow fibres
- B29C70/16—Fibrous reinforcements only characterised by the structure of fibrous reinforcements, e.g. hollow fibres using fibres of substantial or continuous length
- B29C70/22—Fibrous reinforcements only characterised by the structure of fibrous reinforcements, e.g. hollow fibres using fibres of substantial or continuous length oriented in at least two directions forming a two dimensional structure
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
- B29C70/04—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising reinforcements only, e.g. self-reinforcing plastics
- B29C70/28—Shaping operations therefor
- B29C70/40—Shaping or impregnating by compression not applied
- B29C70/42—Shaping or impregnating by compression not applied for producing articles of definite length, i.e. discrete articles
- B29C70/46—Shaping or impregnating by compression not applied for producing articles of definite length, i.e. discrete articles using matched moulds, e.g. for deforming sheet moulding compounds [SMC] or prepregs
- B29C70/48—Shaping or impregnating by compression not applied for producing articles of definite length, i.e. discrete articles using matched moulds, e.g. for deforming sheet moulding compounds [SMC] or prepregs and impregnating the reinforcements in the closed mould, e.g. resin transfer moulding [RTM], e.g. by vacuum
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29D—PRODUCING PARTICULAR ARTICLES FROM PLASTICS OR FROM SUBSTANCES IN A PLASTIC STATE
- B29D99/00—Subject matter not provided for in other groups of this subclass
- B29D99/0025—Producing blades or the like, e.g. blades for turbines, propellers, or wings
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29L—INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
- B29L2031/00—Other particular articles
- B29L2031/08—Blades for rotors, stators, fans, turbines or the like, e.g. screw propellers
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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
- F05D2220/00—Application
- F05D2220/30—Application in turbines
- F05D2220/36—Application in turbines specially adapted for the fan of turbofan engines
Definitions
- Composite materials offer potential design improvements in gas turbine engines. For example, in recent years composite materials have been replacing metals in gas turbine engines, for example in fan blades, because of their high strength and low weight. Most metal gas turbine engine fan blades are titanium alloy. The ductility of titanium fan blades enables the fan to incur a bird strike and remain operable or be safely shut down, as well as other requirements. The same requirements apply to composite fan blades.
- a composite airfoil has a root, which connects to the fan mechanism, and a tip opposite the root.
- a composite airfoil for a turbine engine fan blade is typically designed with a divergent root portion known as a dovetail root. The thickness of the airfoil changes over a short length at the dovetail root.
- the dovetail root enables the airfoil to withstand typical operational loads from rotation and bending and loads from foreign object strikes.
- the composite airfoil can have a hybrid construction with a three-dimensional woven core at the center and two-dimensional filament reinforced plies or laminations on either side, can be completely woven with no plies or laminations or can be made completely of two-dimensional plies.
- individual two-dimensional laminations typically are cut and stacked in a mold with the woven core.
- the woven core extends from the root to the tip of the airfoil and the plies are stacked on either side of the woven core to form the desired exterior surface profile.
- the mold is injected with a resin or matrix material using a resin transfer molding process and cured. Completely woven blade preforms can be placed in a mold and injected with a resin or matrix material without the laminations added.
- Fan blades properties can be changed throughout different regions of the blade by various methods, such as changing the weave pattern throughout the blade and changing the laminate architecture (i.e. stacking sequence and/or orientation of plies). This can help a blade to withstand impact damage, for example at locations where it is susceptible to foreign object damage.
- a composite airfoil includes a woven preform with warp yarns of a first material, the preform with a tip, root, leading edge, trailing edge and an intermediate region positioned between the root and the tip; and a first matrix made of a first resin maintaining the relative positions of the preform yarns.
- the composite blade further includes at least one of: fill yarns of a second material in the woven preform; and a second matrix made of a second resin maintaining the relative positions of the preform yarns in a portion of the airfoil.
- a method of forming a composite airfoil includes weaving warp yarns and fill yarns to form a woven preform; inserting the preform into a mold; injecting a first portion of the mold with a first resin to form a first matrix for maintaining the relative positions of the yarns; injecting a second portion of the mold with a second resin to form a second matrix for maintaining the relative positions of the yarns; and curing the resins.
- FIG. 1 is a cross-sectional view of a gas turbine engine having a turbofan.
- FIG. 2A is a perspective view of a composite fan blade for the turbofan.
- FIG. 2B is an enlarged view of a portion of the preform of FIG. 4 a showing a two-dimensional weave with warp fibers and fill fibers.
- FIG. 3 is an enlarged cross-sectional view of a preform for the composite fan blade having a three dimensional weave pattern.
- FIG. 1 is a cross-sectional view of gas turbine engine 10 , which includes turbofan 12 , compressor section 14 , combustor section 16 and turbine section 18 .
- Compressor section 14 includes low-pressure compressor 20 and high-pressure compressor 22 . Air is taken in through fan 12 as fan 12 spins. A portion of the inlet air is directed to compressor section 14 where it is compressed by a series of rotating blades and non-rotating vanes. The compressed air is mixed with fuel, and then ignited in combustor section 16 . The combustion exhaust is directed to turbine section 18 . Blades and vanes in turbine section 18 extract kinetic energy from the exhaust to turn shaft 24 and provide power output for engine 10 .
- the engine may optionally include a reduction gear (not shown) between the compressor and the fan.
- bypass air The portion of inlet air which is taken in through fan 12 and not directed through compressor section 14 is typically referred to as bypass air.
- Bypass air is directed through bypass duct 26 by guide vanes 28 . Then the bypass air flows through opening 30 to cool combustor section 16 , high-pressure compressor 22 and turbine section 18 .
- Fan 12 includes a plurality of composite blades 32 .
- FIG. 2A illustrates one composite airfoil, in this case a fan blade 32
- FIG. 2B is an enlarged view of a portion of preform 48 showing a two-dimensional weave with warp fibers 50 and fill fibers 52
- FIGS. 2A-2B include airfoil 33 , leading edge 34 , trailing edge 36 , pressure side (not shown), suction side 38 , tip 40 , intermediate region 42 , root 44 , preform 48 , warp fibers 50 (made of a first material) and fill fibers 52 (made of a second material), first matrix 54 and second matrix 56 .
- Root 44 is opposite tip 40
- intermediate region 42 is between root 44 and tip 40 .
- Dovetail root 44 has a divergent shape such that root 44 is thicker than intermediate region 42 and tip 40 .
- Composite blade 32 is connected to the fan mechanism of turbofan 12 by root 44 .
- the additional thickness of root 44 enables composite blade 32 to withstand forces from standard operation and from foreign object impacts.
- Preform 48 is a woven core formed from two-dimensional weaves, as shown in FIG. 2B .
- Warp yarns 50 extend in the longitudinal or spanwise direction of the blade, and fill yarns 52 extend in the chordwise direction.
- Two-dimensional weaves may be used with other two dimensional weaves to form preform 48 .
- preform can be stacked in a mold, injected with resins to form matrix 54 and matrix 56 and cured.
- the yarns of preform 48 are formed from bundles of fibers.
- Example fibers for the yarns of preform 48 include but are not limited to graphite fibers, glass fibers, silicon carbide fibers and boron fibers and combinations thereof.
- Warp fibers 52 are made of a high-strength material, for example, a material with about 900 ksi tensile strength.
- Fill fibers 50 are made of a high stiffness material, for example, a material with about 80 Msi tensile modulus.
- Example resins to form matrix include but are not limited to epoxy resins and epoxy resins containing additives such as rubber particulates or other toughening agents.
- First matrix 54 is high-toughness and is used in tip 40 and intermediate region 42 of blade 32 and is designed to give tip 40 region of blade 32 greater impact resistance, as this is the region most susceptible to bird strike.
- Second matrix 52 is used in root 44 of blade, and is a high-strength matrix designed to give root 44 greater static strength properties, including in-plane strength and interlaminar strength. As root 44 of blade is thick in comparison to airfoil 33 , and the relative impact velocity in root 44 is comparatively lower, local bird strike impact damage in that region is not general a design driver. Therefore, matrix 52 is designed to be high strength to improve resistance to bending from impacts in other regions of blade 32 .
- blades can be susceptible in differing amounts to damage in different regions, it is sometimes desirable to vary blade characteristics and properties according to the region of the blade.
- the hollow cavities were oriented spanwise in the root to optimize longitudinal stiffness and chordwise at the tip to improve bird impact resistance.
- Blade 32 is able to better resist bird strike and other abnormal loading by varying materials throughout blade 32 .
- Near tip 40 where bird-strike is more likely, high-toughness impact resistant matrix 54 is used.
- high-strength matrix 56 is used.
- high-strength warp fibers 52 are used to improve blade 32 strength properties in the spanwise direction, and high-stiffness fill fibers 52 are used to improve resistance to deformation in the chordwise direction.
- blade 32 structural properties can be locally tailored to improve blade 32 weight and performance.
- FIGS. 2A-2B The embodiment shown in FIGS. 2A-2B is for example purposes only, and could be varied depending on system requirements.
- different fibers may be used in different 2-dimensional woven plies, with the same fibers being used within each ply.
- more or fewer matrix materials may be used in blade 32 , or matrix material may be the only material varied throughout the blade.
- FIG. 3 is an enlarged cross-sectional view of preform 48 for a composite fan blade having a three dimensional weave pattern, and includes warp weaver yarns 62 and 64 , stuffer yarns 66 and fill yarns 60 .
- Preform 48 is a three-dimensional woven core formed from a plurality of yarns as described further below. In the example shown, preform 48 extends the spanwise length of composite blade 32 from root 44 to tip 40 the chordwise width of composite blade 32 from leading edge 34 to trailing edge 36 . In some embodiments, preform 48 would not extend the entire spanwise length or chorwise width of the blade, and/or can have laminate sections positioned on either side of preform 48 .
- Yarns 62 , 64 and 66 extend in the longitudinal (or spanwise) direction of preform 48 .
- Fill yarns 60 are placed at a 90 degree angle to the direction of warp weaver yarns 62 and 64 , and stuffer yarns 66 and are aligned in the chordwise direction of preform 48 .
- Warp weaver yarns 62 and 64 are woven with fill yarns 60 to interlock the yarns.
- Warp weaver yarns 64 interlock fill yarns 60 .
- Stuffer yarns 66 extend between fill yarns 60 . Stuffer yarns 66 do not interlock with fill yarns 60 .
- yarns 62 , 64 and 66 extend through separate warp yarn planes. A single warp yarn plane contains only one of yarns 62 , 64 and 66 .
- the material used for yarns 60 , 62 , 64 and 66 can be varied to locally tailor blade 32 properties. This can help to increase strength and/or stiffness in particular regions of the blade, making it better able to resist damage from a foreign object strike. Additionally, as discussed in relation to FIGS. 2A-2B , the matrix material used in blade 32 can be varied according to blade requirements.
- Varying the matrix and fiber materials affects the physical properties of blade 32 , allowing local tailoring to improve blade 32 weight and performance. For example, varying matrix material to provide a high-toughness matrix near tip 40 and a high strength matrix near root 44 can give blade 32 extra resistance to bird strike damage while providing added strength in root 44 to resist bending in the event of a bird strike. This improves the ability of composite blade 32 to withstand stresses from operation and foreign object strikes.
- the use of higher-toughness or strength matrix, or higher strength or stiffness fibers can replace the extra material that was used in some prior art blades to resist bird impact, keeping the weight of blade 32 to a minimum.
- materials could be chosen and placed in regions to offer acoustic dampening properties desired (e.g., use a matrix at the tip that can absorb noise due to high speeds at the tip generating a lot of noise), conform blade 32 to temperature constraints, resist corrosion in areas of blade 32 most susceptible (e.g., tip 40 or leading edge 34 ), resist delamination and locally tailor regions of blade 32 according to any other material properties desired.
- acoustic dampening properties desired e.g., use a matrix at the tip that can absorb noise due to high speeds at the tip generating a lot of noise
- conform blade 32 to temperature constraints e.g., resist corrosion in areas of blade 32 most susceptible (e.g., tip 40 or leading edge 34 ), resist delamination and locally tailor regions of blade 32 according to any other material properties desired.
- Varying materials also provides blade 32 with a great deal of flexibility to locally tailor physical properties without complicating the manufacturing process.
- Preform 48 has a uniform weave pattern despite varying materials used in different regions of blade 32 .
- the uniform weave pattern maintains an integrated structure and improves the ease of manufacturing preform 48 .
- the specific examples of the varying of materials in blade 32 discussed in relation to FIGS. 2A-3 are for example purposes only. Additionally, the weaves shown, the number of fill yarns 60 and warp yarns 62 and 64 , the spacing between fill yarns 60 , the spacing between warp yarns 62 and 64 , the weave pattern and the repetition of the warp yarn planes are provided for example only. Various yarn sizes of fill yarns 60 and warp yarns 62 and 64 , number of fill yarns 60 and warp yarns 62 and 64 and weaving patterns can be used without departing from the scope of this invention.
- a composite airfoil includes a woven preform with warp yarns of a first material, the preform with a tip, root, leading edge, trailing edge and an intermediate region positioned between the root and the tip; and a first matrix made of a first resin maintaining the relative positions of the preform yarns.
- the composite airfoil further includes at least one of: fill yarns of a second material in the woven preform; and a second matrix made of a second resin maintaining the relative positions of the preform yarns in a portion of the airfoil.
- Alternative and/or additional embodiments include the woven preform being a three-dimensional weave and further including stuffer yarns; having a leading edge sheath on the leading edge of the preform; having stuffer yarns of a third material; having a third matrix made of a third resin maintaining the relative positions of the preform yarns in a portion of the airfoil; and/or the airfoil being a blade.
- a composite airfoil includes a preform of yarns woven, the preform having a leading edge, trailing edge, tip region, a root region and an intermediate region positioned between the tip region and the root region, with the yarns comprising warp yarns forming a longitudinal axis of the preform; and fill yarns positioned at about a 90 degree angle to the warp yarns, wherein the warp yarns are a different material than then fill yarns.
- the airfoil further comprises a first matrix to maintain the relative positions of the preform yarns.
- Additional and/or alternative embodiments include the leading edge having a sheath, stuffer yarns in the preform woven with the warp yarns and the fill yarns; the stuffer yarns being a different material than the warp yarns or the fill yarns; a second matrix used in portions of the preform to maintain relative positions of the preform yarns in those portions of the preform, wherein the second matrix has different material properties than the first matrix; the second matrix being used in the tip region of the preform and the first matrix is used in the intermediate and root regions of the preform; a third matrix used in portions of the preform to maintain relative positions of the preform yarns in those portions of the preform, wherein the third matrix has different material properties than the first matrix and the second matrix; the second matrix is used in the tip region of the preform and the first matrix is used in the root region of the preform.
- a method of forming a composite airfoil includes weaving warp yarns and fill yarns to form a woven preform; inserting the preform into a mold; injecting a first portion of the mold with a first resin to form a first matrix for maintaining the relative positions of the yarns; injecting a second portion of the mold with a second resin to form a second matrix for maintaining the relative positions of the yarns; and curing the resins.
- Additional and/or alternative embodiments include the warp yarns being of a different material than the fill yarns; weaving and stuffer yarns to form a three-dimensional woven preform; having one of the warp yarns, the fill yarns and the stuffer yarns is of a different material than the other yarns; having the warp yarns be a first material, the fill yarns be a second material and the stuffer yarns be a third material; the first matrix and the second matrix having different material properties; and/or injecting a third portion of the mold with a third resin to form a third matrix for maintaining the relative positions of the yarns.
Abstract
Description
- Composite materials offer potential design improvements in gas turbine engines. For example, in recent years composite materials have been replacing metals in gas turbine engines, for example in fan blades, because of their high strength and low weight. Most metal gas turbine engine fan blades are titanium alloy. The ductility of titanium fan blades enables the fan to incur a bird strike and remain operable or be safely shut down, as well as other requirements. The same requirements apply to composite fan blades.
- A composite airfoil has a root, which connects to the fan mechanism, and a tip opposite the root. A composite airfoil for a turbine engine fan blade is typically designed with a divergent root portion known as a dovetail root. The thickness of the airfoil changes over a short length at the dovetail root. The dovetail root enables the airfoil to withstand typical operational loads from rotation and bending and loads from foreign object strikes.
- The composite airfoil can have a hybrid construction with a three-dimensional woven core at the center and two-dimensional filament reinforced plies or laminations on either side, can be completely woven with no plies or laminations or can be made completely of two-dimensional plies. To form the composite airfoil with a woven core and laminations, individual two-dimensional laminations typically are cut and stacked in a mold with the woven core. The woven core extends from the root to the tip of the airfoil and the plies are stacked on either side of the woven core to form the desired exterior surface profile. The mold is injected with a resin or matrix material using a resin transfer molding process and cured. Completely woven blade preforms can be placed in a mold and injected with a resin or matrix material without the laminations added.
- Fan blades properties can be changed throughout different regions of the blade by various methods, such as changing the weave pattern throughout the blade and changing the laminate architecture (i.e. stacking sequence and/or orientation of plies). This can help a blade to withstand impact damage, for example at locations where it is susceptible to foreign object damage.
- A composite airfoil includes a woven preform with warp yarns of a first material, the preform with a tip, root, leading edge, trailing edge and an intermediate region positioned between the root and the tip; and a first matrix made of a first resin maintaining the relative positions of the preform yarns. The composite blade further includes at least one of: fill yarns of a second material in the woven preform; and a second matrix made of a second resin maintaining the relative positions of the preform yarns in a portion of the airfoil.
- A method of forming a composite airfoil includes weaving warp yarns and fill yarns to form a woven preform; inserting the preform into a mold; injecting a first portion of the mold with a first resin to form a first matrix for maintaining the relative positions of the yarns; injecting a second portion of the mold with a second resin to form a second matrix for maintaining the relative positions of the yarns; and curing the resins.
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FIG. 1 is a cross-sectional view of a gas turbine engine having a turbofan. -
FIG. 2A is a perspective view of a composite fan blade for the turbofan. -
FIG. 2B is an enlarged view of a portion of the preform ofFIG. 4 a showing a two-dimensional weave with warp fibers and fill fibers. -
FIG. 3 is an enlarged cross-sectional view of a preform for the composite fan blade having a three dimensional weave pattern. -
FIG. 1 is a cross-sectional view ofgas turbine engine 10, which includesturbofan 12,compressor section 14,combustor section 16 andturbine section 18.Compressor section 14 includes low-pressure compressor 20 and high-pressure compressor 22. Air is taken in throughfan 12 asfan 12 spins. A portion of the inlet air is directed tocompressor section 14 where it is compressed by a series of rotating blades and non-rotating vanes. The compressed air is mixed with fuel, and then ignited incombustor section 16. The combustion exhaust is directed toturbine section 18. Blades and vanes inturbine section 18 extract kinetic energy from the exhaust to turnshaft 24 and provide power output forengine 10. The engine may optionally include a reduction gear (not shown) between the compressor and the fan. - The portion of inlet air which is taken in through
fan 12 and not directed throughcompressor section 14 is typically referred to as bypass air. Bypass air is directed throughbypass duct 26 by guide vanes 28. Then the bypass air flows through opening 30 tocool combustor section 16, high-pressure compressor 22 andturbine section 18.Fan 12 includes a plurality ofcomposite blades 32. -
FIG. 2A illustrates one composite airfoil, in this case afan blade 32, andFIG. 2B is an enlarged view of a portion ofpreform 48 showing a two-dimensional weave with warp fibers 50 and fillfibers 52.FIGS. 2A-2B includeairfoil 33, leadingedge 34,trailing edge 36, pressure side (not shown),suction side 38,tip 40,intermediate region 42,root 44,preform 48, warp fibers 50 (made of a first material) and fill fibers 52 (made of a second material),first matrix 54 andsecond matrix 56. Root 44 isopposite tip 40, andintermediate region 42 is betweenroot 44 andtip 40. - Dovetail
root 44 has a divergent shape such thatroot 44 is thicker thanintermediate region 42 andtip 40.Composite blade 32 is connected to the fan mechanism ofturbofan 12 byroot 44. The additional thickness ofroot 44 enablescomposite blade 32 to withstand forces from standard operation and from foreign object impacts. -
Preform 48 is a woven core formed from two-dimensional weaves, as shown inFIG. 2B . Warp yarns 50 extend in the longitudinal or spanwise direction of the blade, and fillyarns 52 extend in the chordwise direction. Two-dimensional weaves may be used with other two dimensional weaves to formpreform 48. To formcomposite blade 32, preform can be stacked in a mold, injected with resins to formmatrix 54 andmatrix 56 and cured. - The yarns of
preform 48 are formed from bundles of fibers. Example fibers for the yarns ofpreform 48 include but are not limited to graphite fibers, glass fibers, silicon carbide fibers and boron fibers and combinations thereof.Warp fibers 52 are made of a high-strength material, for example, a material with about 900 ksi tensile strength. Fill fibers 50 are made of a high stiffness material, for example, a material with about 80 Msi tensile modulus. - Example resins to form matrix include but are not limited to epoxy resins and epoxy resins containing additives such as rubber particulates or other toughening agents.
First matrix 54 is high-toughness and is used intip 40 andintermediate region 42 ofblade 32 and is designed to givetip 40 region ofblade 32 greater impact resistance, as this is the region most susceptible to bird strike.Second matrix 52 is used inroot 44 of blade, and is a high-strength matrix designed to giveroot 44 greater static strength properties, including in-plane strength and interlaminar strength. Asroot 44 of blade is thick in comparison toairfoil 33, and the relative impact velocity inroot 44 is comparatively lower, local bird strike impact damage in that region is not general a design driver. Therefore,matrix 52 is designed to be high strength to improve resistance to bending from impacts in other regions ofblade 32. - As blades can be susceptible in differing amounts to damage in different regions, it is sometimes desirable to vary blade characteristics and properties according to the region of the blade. For example, in past hollow metallic blades, the hollow cavities were oriented spanwise in the root to optimize longitudinal stiffness and chordwise at the tip to improve bird impact resistance.
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Blade 32 is able to better resist bird strike and other abnormal loading by varying materials throughoutblade 32. Neartip 40, where bird-strike is more likely, high-toughness impactresistant matrix 54 is used. Inroot 44, where resistance to bending is desired, high-strength matrix 56 is used. In weave, high-strength warp fibers 52 are used to improveblade 32 strength properties in the spanwise direction, and high-stiffness fill fibers 52 are used to improve resistance to deformation in the chordwise direction. By varying materials in blade 32 (fill fibers 50,warp fibers 52,matrix 54, 56),blade 32 structural properties can be locally tailored to improveblade 32 weight and performance. - The embodiment shown in
FIGS. 2A-2B is for example purposes only, and could be varied depending on system requirements. For example, different fibers may be used in different 2-dimensional woven plies, with the same fibers being used within each ply. Or more or fewer matrix materials may be used inblade 32, or matrix material may be the only material varied throughout the blade. -
FIG. 3 is an enlarged cross-sectional view ofpreform 48 for a composite fan blade having a three dimensional weave pattern, and includeswarp weaver yarns stuffer yarns 66 and fill yarns 60. -
Preform 48 is a three-dimensional woven core formed from a plurality of yarns as described further below. In the example shown, preform 48 extends the spanwise length ofcomposite blade 32 fromroot 44 to tip 40 the chordwise width ofcomposite blade 32 from leadingedge 34 to trailingedge 36. In some embodiments, preform 48 would not extend the entire spanwise length or chorwise width of the blade, and/or can have laminate sections positioned on either side ofpreform 48. -
Yarns preform 48. Fill yarns 60 are placed at a 90 degree angle to the direction ofwarp weaver yarns stuffer yarns 66 and are aligned in the chordwise direction ofpreform 48.Warp weaver yarns Warp weaver yarns 64 interlock fill yarns 60. -
Stuffer yarns 66 extend between fill yarns 60.Stuffer yarns 66 do not interlock with fill yarns 60. One skilled in the art will recognize thatyarns yarns - The material used for
yarns blade 32 properties. This can help to increase strength and/or stiffness in particular regions of the blade, making it better able to resist damage from a foreign object strike. Additionally, as discussed in relation toFIGS. 2A-2B , the matrix material used inblade 32 can be varied according to blade requirements. - Varying the matrix and fiber materials affects the physical properties of
blade 32, allowing local tailoring to improveblade 32 weight and performance. For example, varying matrix material to provide a high-toughness matrix neartip 40 and a high strength matrix nearroot 44 can giveblade 32 extra resistance to bird strike damage while providing added strength inroot 44 to resist bending in the event of a bird strike. This improves the ability ofcomposite blade 32 to withstand stresses from operation and foreign object strikes. The use of higher-toughness or strength matrix, or higher strength or stiffness fibers can replace the extra material that was used in some prior art blades to resist bird impact, keeping the weight ofblade 32 to a minimum. Additionally materials could be chosen and placed in regions to offer acoustic dampening properties desired (e.g., use a matrix at the tip that can absorb noise due to high speeds at the tip generating a lot of noise), conformblade 32 to temperature constraints, resist corrosion in areas ofblade 32 most susceptible (e.g.,tip 40 or leading edge 34), resist delamination and locally tailor regions ofblade 32 according to any other material properties desired. - Varying materials also provides
blade 32 with a great deal of flexibility to locally tailor physical properties without complicating the manufacturing process.Preform 48 has a uniform weave pattern despite varying materials used in different regions ofblade 32. The uniform weave pattern maintains an integrated structure and improves the ease ofmanufacturing preform 48. - The specific examples of the varying of materials in
blade 32 discussed in relation toFIGS. 2A-3 are for example purposes only. Additionally, the weaves shown, the number of fill yarns 60 andwarp yarns warp yarns warp yarns warp yarns - A composite airfoil includes a woven preform with warp yarns of a first material, the preform with a tip, root, leading edge, trailing edge and an intermediate region positioned between the root and the tip; and a first matrix made of a first resin maintaining the relative positions of the preform yarns. The composite airfoil further includes at least one of: fill yarns of a second material in the woven preform; and a second matrix made of a second resin maintaining the relative positions of the preform yarns in a portion of the airfoil.
- Alternative and/or additional embodiments include the woven preform being a three-dimensional weave and further including stuffer yarns; having a leading edge sheath on the leading edge of the preform; having stuffer yarns of a third material; having a third matrix made of a third resin maintaining the relative positions of the preform yarns in a portion of the airfoil; and/or the airfoil being a blade.
- A composite airfoil includes a preform of yarns woven, the preform having a leading edge, trailing edge, tip region, a root region and an intermediate region positioned between the tip region and the root region, with the yarns comprising warp yarns forming a longitudinal axis of the preform; and fill yarns positioned at about a 90 degree angle to the warp yarns, wherein the warp yarns are a different material than then fill yarns. The airfoil further comprises a first matrix to maintain the relative positions of the preform yarns.
- Additional and/or alternative embodiments include the leading edge having a sheath, stuffer yarns in the preform woven with the warp yarns and the fill yarns; the stuffer yarns being a different material than the warp yarns or the fill yarns; a second matrix used in portions of the preform to maintain relative positions of the preform yarns in those portions of the preform, wherein the second matrix has different material properties than the first matrix; the second matrix being used in the tip region of the preform and the first matrix is used in the intermediate and root regions of the preform; a third matrix used in portions of the preform to maintain relative positions of the preform yarns in those portions of the preform, wherein the third matrix has different material properties than the first matrix and the second matrix; the second matrix is used in the tip region of the preform and the first matrix is used in the root region of the preform.
- A method of forming a composite airfoil includes weaving warp yarns and fill yarns to form a woven preform; inserting the preform into a mold; injecting a first portion of the mold with a first resin to form a first matrix for maintaining the relative positions of the yarns; injecting a second portion of the mold with a second resin to form a second matrix for maintaining the relative positions of the yarns; and curing the resins.
- Additional and/or alternative embodiments include the warp yarns being of a different material than the fill yarns; weaving and stuffer yarns to form a three-dimensional woven preform; having one of the warp yarns, the fill yarns and the stuffer yarns is of a different material than the other yarns; having the warp yarns be a first material, the fill yarns be a second material and the stuffer yarns be a third material; the first matrix and the second matrix having different material properties; and/or injecting a third portion of the mold with a third resin to form a third matrix for maintaining the relative positions of the yarns.
- While the invention has been described with reference to an exemplary embodiment(s), it will be understood by those skilled in the art that various changes may be made and equivalents may be substituted for elements thereof without departing from the scope of the invention. In addition, many modifications may be made to adapt a particular situation or material to the teachings of the invention without departing from the essential scope thereof. Therefore, it is intended that the invention not be limited to the particular embodiment(s) disclosed, but that the invention will include all embodiments falling within the scope of the appended claims.
Claims (20)
Priority Applications (2)
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US13/408,099 US20130224035A1 (en) | 2012-02-29 | 2012-02-29 | Composite airfoil with local tailoring of material properties |
PCT/US2013/026661 WO2013172893A2 (en) | 2012-02-29 | 2013-02-19 | Composite airfoil with local tailoring of material properties |
Applications Claiming Priority (1)
Application Number | Priority Date | Filing Date | Title |
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US13/408,099 US20130224035A1 (en) | 2012-02-29 | 2012-02-29 | Composite airfoil with local tailoring of material properties |
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US20130224035A1 true US20130224035A1 (en) | 2013-08-29 |
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ID=49003080
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US13/408,099 Abandoned US20130224035A1 (en) | 2012-02-29 | 2012-02-29 | Composite airfoil with local tailoring of material properties |
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FR3107000A1 (en) * | 2020-02-10 | 2021-08-13 | Safran Aircraft Engines | Fibrous texture to make a blower blade in composite material |
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