Turbine blade with three-dimensional CMC construction elements

Patent metadata

Field	Value
Publication number	US-10577939-B2
Application number	US-201615340684-A
Country	US
Kind code	B2
Filing date	Nov 1, 2016
Priority date	Nov 1, 2016
Publication date	Mar 3, 2020
Grant date	Mar 3, 2020

Abstract

An ceramic matrix composite blade for use in a gas turbine engine is disclosed. The ceramic matrix composite blade includes a root, an airfoil, and a platform located between the root and the airfoil.

First claim

What is claimed is:

1. A ceramic matrix composite blade comprising a root, a platform, and an airfoil adapted for use in a gas turbine engine, a core having a proximal end and a distal end, the core comprising reinforcing fibers in a ceramic matrix material, and a wrap comprising three-dimensional reinforcing fibers in a ceramic matrix material, the wrap arranged to extend under the proximal end of the core to form an outer surface of the root and the wrap being configured to contact a disk when the ceramic matrix composite blade is assembled into a turbine wheel, and a platform ply arranged to overlie the platform without extending upwardly into the airfoil or downwardly into the root, wherein the wrap extends outwardly away from the core to form at least a portion of the platform, and wherein the core is exposed between a pressure-side section and suction side section of the wrap along a leading edge of the airfoil and wherein the core is exposed between a pressure-side section and suction side section of the wrap along a trailing edge of the airfoil.

2. The ceramic matrix composite blade of claim 1 , wherein the platform ply comprises one of a one-dimensional ply of reinforcing fibers, a two-dimensional ply of reinforcing fibers, a three-dimensional ply of reinforcing fibers, a mat ply of reinforcing fibers, and a conversion layer.

3. The ceramic matrix composite blade of claim 2 , wherein the platform ply is arranged to surround the airfoil and includes a slit joint that extends from the airfoil to an edge of the platform at a location having the smallest distance from the airfoil to the edge of the platform.

4. The ceramic matrix composite blade of claim 1 , wherein the wrap further includes a pressure side section extending upwardly from the platform towards a distal end and a suction side section extending upwardly from the platform towards the distal end to locate a portion of the core therebetween.

5. The ceramic matrix composite blade of claim 4 , wherein the wrap further includes a first tip shroud section located spaced-apart platform and extending outwardly away from the core.

6. The ceramic matrix composite blade of claim 4 , further comprising an airfoil ply that extends around the leading edge of the airfoil forming a seam along the trailing edge of the airfoil, wherein the airfoil ply terminates at the platform and does not extend downwardly into the platform or root.

7. A ceramic matrix composite blade comprising a root, a platform, and an airfoil adapted for use in a gas turbine engine, a core having a proximal end and a distal end, the core comprising two-dimensional reinforcing fibers in a ceramic matrix material, and a wrap comprising three-dimensional reinforcing fibers in a ceramic matrix material, the wrap arranged to extend under the proximal end of the core to form an outer surface of the root and the wrap being configured to contact a disk when the ceramic matrix composite blade is assembled into a turbine wheel, wherein the wrap extends outwardly away from the core to form at least a portion of the platform, and wherein the two-dimensional reinforcing fibers of the core are unbalanced such that that the core includes more fibers that extend from the proximal end to the distal end of the core than fibers that across the core.

8. The ceramic matrix composite blade of claim 7 , wherein the wrap includes a first section, a second section, and a third section that cooperate to extend around the proximal end of the core, the second section is arranged to extend under the proximal end of the core and extends between and interconnects the first section and the third section, and each of the first section and the third section extends upwardly away from the second section from the proximal end towards a distal end to locate the proximal end of the core therebetween.

9. A ceramic matrix composite blade comprising a root, a platform, and an airfoil adapted for use in a gas turbine engine, a core having a proximal end and a distal end, the core comprising reinforcing fibers in a ceramic matrix material, and a wrap comprising three-dimensional reinforcing fibers in a ceramic matrix material, the wrap arranged to extend under the proximal end of the core to form an outer surface of the root and the wrap being configured to contact a disk when the ceramic matrix composite blade is assembled into a turbine wheel, wherein the wrap includes a first section, a second section, and a third section that cooperate to extend around the proximal end of the core, the second section is arranged to extend under the proximal end of the core and extends between and interconnects the first section and the third section, and each of the first section and the third section extends upwardly away from the second section from the proximal end towards a distal end to locate the proximal end of the core therebetween, and wherein the second section includes a spreader extending into the proximal end of the core to locate a first portion of the core between the spreader and the first section of the wrap and a second portion of the core between the spreader and the third section of the wrap.

10. A ceramic matrix composite blade formed of comprising a wrap of three-dimensional woven reinforcement in a ceramic matrix composite, the wrap comprising:
a root configured to be retained in a disk when the blade is assembled into a turbine wheel,
a platform arranged to define a portion of a gas path, and
an airfoil shaped to interact with air passing through the gas path,
wherein the wrap is arranged to define a forward structural seam provided at an interface of ends of the wrap that extends along only the root and an aft structural seam provided at an interface of ends of the wrap that extends along the root, the platform, and the airfoil.

11. The ceramic matrix composite blade of claim 10 , wherein the wrap is arranged to form a leading edge of the airfoil.

12. The ceramic matrix composite blade of claim 11 , wherein the airfoil further includes an airfoil core located within the airfoil formed by the wrap.

13. The ceramic matrix composite blade of claim 12 , wherein the airfoil core is formed of two-dimensional woven reinforcement in a ceramic matrix composite.

14. The ceramic matrix composite blade of claim 13 , wherein the two-dimensional reinforcing fibers of the core are unbalanced such that that the core includes more fibers that extend from the proximal end to the distal end of the core than fibers that across the core.

Assignees

• Rolls Royce Corp
• Rolls Royce Nam Tech Inc

Inventors

• Vetters Daniel K
• Thomas David J

Classifications

• F01D5/284

  Selection of ceramic materials · CPC title

• F01D5/147 Primary

  Construction, i.e. structural features, e.g. of weight-saving hollow blades (F01D5/148, F01D5/16 and F01D5/20 take precedence; blade shape F01D5/141; blades with cooling or heating channels or cavities F01D5/18; heating, heat-insulating or cooling means on blades F01D5/18) · CPC title

• F05D2240/80

  Platforms for stationary or moving blades · CPC title

• F05D2220/32

  in gas turbines · CPC title

• F04D29/384

  characterised by form · CPC title