Ceramic matrix composite turbine vanes and vane ring assemblies

The present disclosure is related to turbine vanes comprising ceramic matrix composite materials and vane ring assemblies including the same. The turbine vane may include mount extensions that extend outside a primary gas path to provide a point of coupling for attaching the turbine vane to a support structure.

FIELD OF THE DISCLOSURE

The present disclosure relates generally to vanes used in gas turbine engines, and more specifically to vanes incorporating ceramic matrix composite materials.

BACKGROUND

Products of the combustion reaction directed into the turbine flow over airfoils included in stationary vanes and rotating blades of the turbine. The interaction of combustion products with the airfoils heats the airfoils to temperatures that require the airfoils to be made from high-temperature resistant materials and/or to be actively cooled by supplying relatively cool air to the vanes and blades. To this end, some airfoils for vanes and blades are incorporating composite materials adapted to withstand very high temperatures. Design and manufacture of vanes and blades from composite materials presents challenges because of the geometry and strength required for the parts.

SUMMARY

A vane ring assembly for use in a gas turbine engine may include a plurality of individual turbine vanes and a support structure. The turbine vanes may be made of ceramic matrix composite materials and are arranged circumferentially adjacent to one another to form a ring that extends around a central axis. The support structure comprises metallic materials and engages a mount extension included in the turbine vane to couple the turbine vane to the support structure and provide a simply supported load path from an airfoil of the turbine vane to the support structure so that aerodynamic loading of the airfoil may be directly transmitted from the airfoil to the support structure.

In some embodiments, the turbine vane includes an airfoil, inner and outer platforms, and inner and outer mount extensions. The airfoil is shaped to redirect air moving through a primary gas path within the gas turbine engine. The platforms extend circumferentially from the airfoil at least partway about the central axis to define a boundary of the primary gas path. The mount extensions extend outside the primary gas path to provide a point of coupling for attaching the turbine vane to a support structure at a location where temperatures may be lower than within the primary gas path.

In some embodiments, at least some components of the airfoil are arranged within an airfoil footprint of the airfoil arranged in the primary gas path when the turbine vane is viewed in a radially-inwardly looking direction toward the central axis.

In some embodiments, the mount extension includes at least some components of the airfoil that extend through the platform and out of the primary gas path so that aerodynamic loading of the airfoil may be directly transmitted from the airfoil to the support structure.

In some embodiments, the airfoil includes an airfoil core tube, an airfoil cover ply, and an airfoil trailing edge fill body. The airfoil core tube is shaped to form a passageway that extends radially through the airfoil. The airfoil cover ply is arranged around the airfoil core tube and the airfoil trailing edge fill body to provide an outer surface of the airfoil within the primary gas path. The airfoil cover ply shields the airfoil core tube and the airfoil trailing edge fill body from air moving through the primary gas path.

In some embodiments, the platform includes platform panel and a platform ply. The platform panel extends circumferentially from the airfoil at least partway about the central axis to define a boundary of the primary gas path. The platform ply is arranged so that if forms a radially facing outer surface of the platform.

In some embodiments, the mount extension further includes an extension over ply of reinforcement material, an extension fill body, and a plurality of datum features. The extension over ply is arranged around at least some of the components of the airfoil outside of the primary gas path to provide an outer surface of the mount extension facing circumferentially relative to the central axis away from the components of the airfoil outside the primary gas path. The plurality of datum features extend out of the airfoil footprint when the turbine vane is viewed in a radially-inwardly looking direction toward the central axis. The plurality of datum features are configured to be machined so as to control location of the turbine vane relative to the support structure.

In some embodiments, the extension over ply of reinforcement material includes a mount portion, a fillet portion, and a retainer portion. The mount portion provides the outer surface of the mount extension. The fillet portion extends radially from the mount portion toward the platform and is shaped to provide a radius at the interface of the platform and the mount extension. The retainer portion extends circumferentially along a radially facing surface of platform and is sandwiched radially between the platform panel and the platform ply of the platform.

According to another aspect of the present disclosure, a turbine vane may include an airfoil, inner and outer platforms, and inner and outer mount extensions. The airfoil is shaped to redirect air moving through a primary gas path within the gas turbine engine. The platforms extend circumferentially from the airfoil at least partway about the central axis to define a boundary of the primary gas path. The mount extensions extend outside the primary gas path to provide a point of coupling for attaching the turbine vane to a support structure.

In some embodiments, at least some components of the airfoil are arranged within an airfoil footprint of the airfoil arranged in the primary gas path when the turbine vane is viewed in a radially-inwardly looking direction toward the central axis.

In some embodiments, the mount extension includes at least some components of the airfoil that extend through the platform and out of the primary gas path so that aerodynamic loading of the airfoil may be directly transmitted from the airfoil to the support structure.

In some embodiments, the airfoil includes an airfoil core tube, an airfoil cover ply, and an airfoil trailing edge fill body. The airfoil core tube is shaped to form a passageway that extends radially through the airfoil. The airfoil cover ply is arranged around the airfoil core tube and the airfoil trailing edge fill body to provide an outer surface of the airfoil within the primary gas path. The airfoil cover ply shields the airfoil core tube and the airfoil trailing edge fill body from air moving through the primary gas path. The airfoil trailing edge fill body is shaped to form the trailing edge of the airfoil.

In some embodiments, the airfoil cover ply includes an airfoil interior cover ply and an airfoil exterior cover ply. The interior cover ply is arranged around the at least some components of the airfoil and extends between a radially outermost end of the turbine vane and a radially innermost end of the turbine vane. The exterior cover ply is arranged around the airfoil core tube, the airfoil trailing edge fill body, and the interior cover ply within the primary gas path.

In some embodiments, the airfoil further includes an airfoil fill body. The airfoil fill body is arranged around at least some of the components of the airfoil inside of the primary gas path at the interface of the platform and the airfoil.

In some embodiments, the airfoil exterior cover ply includes an airfoil portion, a fillet portion, and a retainer portion. The airfoil portion provides the inner surface of the airfoil interacting with the air moving through the primary gas path. The fillet portion extends radially from the airfoil portion toward the platform. The fillet portion is shaped to provide a radius at the interface of the platform and the airfoil and engages the airfoil fill body. The retainer portion extends circumferentially along a radially facing surface of platform.

In some embodiments, the platform includes platform panel, an exterior platform ply, and an interior platform ply. The platform panel extends circumferentially from the airfoil at least partway about the central axis to define a boundary of the primary gas path. The exterior platform ply is arranged so that it forms a radially facing outer surface of the platform. The interior platform ply is arranged so that it forms a radially facing inner surface of the platform.

In some embodiments, the mount extension further includes an extension over ply of reinforcement material, an extension fill body, and a plurality of datum features. The extension over ply is arranged around at least some of the components of the airfoil16outside of the primary gas path to provide an outer surface of the mount extension facing circumferentially relative to the central axis away from the components of the airfoil outside the primary gas path. The plurality of datum features extend out of the airfoil footprint when the turbine vane is viewed in a radially-inwardly looking direction toward the central axis. The plurality of datum features are configured to be machined so as to control location of the turbine vane relative to the support structure.

In some embodiments, the extension over ply of reinforcement material includes a mount portion, a fillet portion, and a retainer portion. The mount portion provides the outer surface of the mount extension. The fillet portion extends radially from the mount portion toward the platform and is shaped to provide a radius at the interface of the platform and the mount extension. The retainer portion extends circumferentially along a radially facing surface of platform and is sandwiched radially between the platform panel and the platform ply of the platform.

DETAILED DESCRIPTION OF THE DRAWINGS

A portion of a vane ring assembly10for use in a gas turbine engine is shown illustratively inFIG. 1. The vane ring assembly10is made up of a plurality of individual turbine vanes12and a support structure14. The turbine vanes12comprise ceramic matrix composite materials and are arranged circumferentially adjacent to one another to form a ring that extends around a central axis. The support structure14, shown diagrammatically inFIG. 1, comprises metallic materials and engages a mount extension20included in the turbine vane12to couple the turbine vane12to the support structure14to provide a simply supported load path from an airfoil16of the turbine vane12to the support structure14so that aerodynamic loading of the airfoil16may be directly transmitted from the airfoil16to the support structure14. In some embodiments, the support structure14may be adapted for mounting in a ring or to a turbine case included in the vane ring assembly10.

The turbine vane12includes an airfoil16, inner and outer platforms18, and inner and outer mount extensions20as shown inFIGS. 1 and 2. The airfoil16is shaped to redirect air moving through a primary gas path22within the gas turbine engine. The platforms18extend circumferentially from the airfoil16at least partway about the central axis to define a boundary of the primary gas path22. The mount extensions20extend outside the primary gas path22to provide a point of coupling for attaching the turbine vane12to a support structure14at a location where temperatures may be lower than within or adjacent to the primary gas path.

The mount extension20includes at least some components of the airfoil16that extend through the platform18and out of the primary gas path22as shown inFIGS. 1 and 2. Accordingly, aerodynamic loading of the airfoil may be directly transmitted from the airfoil16to the support structure14. In the illustrative embodiment, the mount extension20includes all of the components of the airfoil16that extend through the platform18and out of the primary gas path22. In other embodiments, the mount extension20may only include some components of the airfoil16as described herein. In the illustrative embodiment, components of the airfoil16that also provide part of the mount extensions20are arranged within a footprint of the airfoil16arranged in the primary gas path22when the turbine vane12is viewed in a radially-inwardly looking direction toward the central axis.

In the illustrative embodiment, the airfoil16, the platforms18, and the mount extensions20come together to form one integral, single-piece turbine vane12as shown inFIG. 1. The interface between the airfoil16, the platform18, and the mount extension20forms a joint therebetween. The joint is reinforced with several reinforcement layers comprising ceramic matrix composite material that are arranged to form a fillet at the joint outside of the gas path22. The layers and fillet reinforcing the joint between the airfoil16, the platform18, and the mount extension20once assembled are infiltrated with matrix material to create one integral single piece turbine vane with no air leakage between the airfoil16and the platforms18.

The construction of the turbine vane12, and in particular of the ceramic-containing reinforcements in the part, is shown in the illustrative embodiments ofFIGS. 1-3. The airfoil16includes an airfoil core tube24, an airfoil cover ply26, and an airfoil trailing edge fill body28as shown inFIGS. 1-3. The airfoil core tube24is shaped to form a passageway30that extends radially through the airfoil16. The airfoil cover ply26is arranged around the airfoil core tube24and the airfoil trailing edge fill body28to provide an outer surface of the airfoil16within the primary gas path22. The airfoil cover ply26shields the airfoil core tube24and the airfoil trailing edge fill body28from air moving through the primary gas path22. The airfoil trailing edge fill body28is shaped to form the trailing edge of the airfoil16. In the illustrative embodiment, the airfoil core tube24, the airfoil cover ply26, and the airfoil trailing edge fill body28all extend through the platform18and out of the primary gas path22to provide part of the mount extension20.

In some embodiments, the airfoil cover ply26may have excess material that extends from the trailing edge of the airfoil16. The excess of material would allow for trailing edge machining operations and improve the aerodynamics of the airfoil16. However, the portion of the airfoil trailing edge fill body28and airfoil cover ply26outside of the gas path22forming the mount extension20would not be machined.

The platform18includes platform panel46and a platform ply48as shown inFIGS. 2 and 3. The platform panel46extends circumferentially from the airfoil16at least partway about the central axis to define a boundary of the primary gas path22. The platform ply48is arranged so that if forms a radially facing outer surface of the platform18.

The mount extension20further includes an extension over ply of reinforcement material52, an extension fill body54, and a plurality of datum features56as shown inFIGS. 1-3. The extension over ply52is arranged around at least some of the components of the airfoil16outside of the primary gas path22to provide an outer surface of the mount extension20facing circumferentially relative to the central axis away from the components of the airfoil16outside the primary gas path22. The extension fill body54is arranged around at least some of the components of the airfoil16outside of the primary gas path22at the interface of the platform18and the mount extension20. The plurality of datum features56extend out of the airfoil footprint when the turbine vane12is viewed in a radially-inwardly looking direction toward the central axis. The plurality of datum features56are configured to be machined so as to control location of the turbine vane12relative to the support structure14.

In the illustrative embodiment, the datum features56extend outside of the airfoil footprint when the turbine vane is viewed in a radially-inwardly looking direction toward the central axis and directly engage the support structure14. The direct engagement of the datum features56to the support structure14allows for the aerodynamic load to be transferred from the airfoil16to the support structure14.

In the illustrative embodiment, the datum features56have a circular cross-sectional shape when viewed from a side of the turbine vane12. In other embodiments, the datum features56may have other suitable cross-sectional shapes.

In the illustrative embodiment, the extension over ply52is arranged around the airfoil core tube24, the airfoil cover ply26, and the airfoil trailing edge fill body28. In other embodiments, the extension over ply52may be arranged around only the airfoil core tube24.

The extension over ply of reinforcement material52includes a mount portion58, a fillet portion60, and a retainer portion62as shown inFIGS. 2 and 3. The mount portion58provides the outer surface of the mount extension20. The fillet portion60extends radially from the mount portion58toward the platform18. The fillet portion60is shaped to provide a radius64at the interface of the platform18and the mount extension20and engages the extension fill body54. The retainer portion62extends circumferentially along a radially facing surface of platform18and is sandwiched radially between the platform panel46and the platform ply48of the platform18.

The layering of the different ply and fill body components26,48,52,54reinforces and seal the joint between the airfoil16, the platform18, and the mount extension20so that no air leaks from the primary gas path22. In the illustrative embodiment, the layering of the different components is located at the joint outside of the gas path22. In other embodiments, additional layering may be included at the joint within the primary gas path22.

In the illustrative embodiment, the radius64of the fillet portion60of the extension over ply52is complementary to a radius68of the extension fill body54. In some embodiments, the extension fill body54may increase in size and therefore resulting in the fillet portion60of the extension over ply52having a greater radius. In other embodiments, the mount portion58of the extension over ply52may have a greater thickness so that the datum features56may be machined more easily.

The turbine vane12may be manufactured in several ways. One method of manufacture may include inserting the airfoil preform16with the airfoil core tube24, airfoil trailing edge fill body28, and the airfoil cover ply26already formed into an airfoil shaped aperture formed in the platform braid preform18, layering the extension fill body50around the outside of the airfoil foot print at the interface between the platform18and the mount extension20, layering the extension over ply52over the components of the airfoil16extending out of the primary gas path22and the extension fill body50, layering the platform ply48over the extension over ply52, infiltrating the entire component to form an integral single piece turbine vane12. The method may also include machining datum features56in the mount extension20to locate the turbine vane12relative to the support structure14.

A portion of a second vane ring assembly210for use in a gas turbine engine is shown illustratively inFIG. 4. The vane ring assembly210is made up of a plurality of individual turbine vanes212and a support structure214. The turbine vanes212comprise ceramic matrix composite materials and are arranged circumferentially adjacent to one another to form a ring that extends around a central axis. The support structure214, shown diagrammatically inFIG. 4, comprises metallic materials and engages a mount extension220included in the turbine vane212to couple the turbine vane212to the support structure214to provide a simply supported load path from an airfoil216of the turbine vane212to the support structure214so that aerodynamic loading of the airfoil216may be directly transmitted from the airfoil216to the support structure214. In some embodiments, the support structure214may be adapted for mounting in a ring or to a turbine case included in the vane ring assembly210.

The turbine vane212includes an airfoil216, inner and outer platforms218, and inner and outer mount extensions220as shown inFIGS. 4-6. The airfoil216is shaped to redirect air moving through a primary gas path222within the gas turbine engine. The platforms218extend circumferentially from the airfoil216at least partway about the central axis to define a boundary of the primary gas path222. In the illustrative embodiment, at least some components of the airfoil216are arranged within an airfoil footprint of the airfoil216arranged in the primary gas path222when the turbine vane212is viewed in a radially-inwardly looking direction toward the central axis. The mount extensions220extend outside the primary gas path222to provide a point of coupling for attaching the turbine vane212to a support structure214.

The mount extension220includes at least some components of the airfoil216that extend through the platform218and out of the primary gas path222so that aerodynamic loading of the airfoil may be directly transmitted from the airfoil216to the support structure214. In the illustrative embodiment, the mount extension220includes all of the components that extends through the platform218and out of the primary gas path222.

In the illustrative embodiment, the airfoil216, the platforms218, and the mount extensions220come together to form one integral single piece turbine vane212as shown inFIG. 4. The interface between the airfoil216, the platform218, and the mount extension220forms a joint therebetween. The joint is reinforced with several reinforcement layers comprising ceramic matrix composite material that are arranged to form a fillet on either side of the joint. The layers and fillet reinforcing the joint between the airfoil216, the platform218, and the mount extension220once assembled are infiltrated with matrix material to create one integral single piece turbine vane with no air leakage between the airfoil216and the platforms218.

The construction of the turbine vane212is shown in the illustrative embodiments ofFIGS. 4-6. The airfoil216includes an airfoil core tube224, an airfoil cover ply226, and an airfoil trailing edge fill body228as shown inFIGS. 4-6. The airfoil core tube224is shaped to form a passageway230that extends radially through the airfoil216. The airfoil cover ply226is arranged around the airfoil core tube224and the airfoil trailing edge fill body228to provide an outer surface of the airfoil216within the primary gas path222. The airfoil cover ply226shields the airfoil core tube224and the airfoil trailing edge fill body228from air moving through the primary gas path222. The airfoil trailing edge fill body228is shaped to form the trailing edge of the airfoil216. In the illustrative embodiment, the airfoil core tube224, the airfoil cover ply226, and the airfoil trailing edge fill body228all extend through the platform218and out of the primary gas path222to provide part of the mount extension220.

In the illustrative embodiment, the airfoil cover ply226includes an airfoil interior cover ply232and an airfoil exterior cover ply234as shown inFIG. 6. The interior cover ply232is arranged around the airfoil core tube224and the airfoil trailing edge fill body228and extends between a radially outermost end of the turbine vane212and a radially innermost end of the turbine vane212. The exterior cover ply234is arranged around the airfoil core tube224, the airfoil trailing edge fill body228, and the interior cover ply232within the primary gas path222.

The airfoil216further includes an airfoil fill body236as shown inFIGS. 5 and 6. The airfoil fill body236is arranged around at least some of the components of the airfoil216inside of the primary gas path222at the interface of the platform218and the airfoil216. In the illustrative embodiment, the airfoil fill body236is arranged around the airfoil core tube224, the airfoil interior cover ply232, and the airfoil trailing edge fill body228. The airfoil exterior cover ply234engages the airfoil fill body236.

In the illustrative embodiments, the airfoil exterior cover ply234includes an airfoil portion238, a fillet portion240, and a retainer portion242as shown inFIG. 6. The airfoil portion238provides the inner surface of the airfoil216interacting with the air moving through the primary gas path222. The fillet portion240extends radially from the airfoil portion238toward the platform218. The fillet portion240is shaped to provide a radius244at the interface of the platform218and the airfoil216and engages the airfoil fill body236. The retainer portion242extends circumferentially along a radially facing surface of platform218.

In some embodiments, the airfoil cover ply226may have excess material that extends from the trailing edge of the airfoil16. The excess of material would allow for trailing edge machining operations and improve the aerodynamics of the airfoil216. However, the portion of the airfoil trailing edge fill body228and airfoil cover ply226outside of the gas path222forming the mount extension220would not be machined.

The platform218includes platform panel246, an exterior platform ply248, and an interior platform ply250as shown inFIGS. 5 and 6. The platform panel246extends circumferentially from the airfoil216at least partway about the central axis to define a boundary of the primary gas path222. The exterior platform ply248is arranged so that it forms a radially facing outer surface of the platform218. The interior platform ply250is arranged so that it forms a radially facing inner surface of the platform218.

The mount extension220further includes an extension over ply of reinforcement material252, an extension fill body254, and a plurality of datum features256as shown inFIGS. 4-6. The extension over ply252is arranged around at least some of the components of the airfoil216outside of the primary gas path222to provide an outer surface of the mount extension220facing circumferentially relative to the central axis away from the components of the airfoil216outside the primary gas path222. The extension fill body254is arranged around at least some of the components of the airfoil216outside of the primary gas path222at the interface of the platform218and the mount extension220. The plurality of datum features256extend out of the airfoil footprint when the turbine vane212is viewed in a radially-inwardly looking direction toward the central axis. The plurality of datum features256are configured to be machined so as to control location of the turbine vane212relative to the support structure214.

In the illustrative embodiment, the datum features256extend outside of the airfoil footprint when the turbine vane is viewed in a radially-inwardly looking direction toward the central axis and directly engage the support structure214. The direct engagement of the datum features256to the support structure214allows for the aerodynamic load to be transferred from the airfoil216to the support structure214.

In the illustrative embodiment, the datum features256have a circular cross-sectional shape when viewed from a side of the turbine vane212. In other embodiments, the datum features256may have other suitable cross-sectional shapes.

In the illustrative embodiment, the extension over ply252is arranged around the airfoil core tube224, the airfoil cover ply226, and the airfoil trailing edge fill body228. In other embodiments, the extension over ply252may be arranged around only the airfoil core tube224.

The extension over ply of reinforcement material252includes a mount portion258, a fillet portion260, and a retainer portion262as shown inFIGS. 5 and 6. The mount portion258provides the outer surface of the mount extension220. The fillet portion260extends radially from the mount portion258toward the platform218. The fillet portion260is shaped to provide a radius264at the interface of the platform218and the mount extension220and engages the extension fill body254. The retainer portion262extends circumferentially along a radially facing surface of platform218and is sandwiched radially between the platform panel246and the exterior platform ply248of the platform218.

In the illustrative embodiment, the retainer portion242of the airfoil exterior cover ply234is sandwiched radially between the platform panel246and the interior platform ply250. The layering of the different ply and fill body components232,234,236,248,250,252,254reinforces and seal the joint between the airfoil216, the platform218, and the mount extension220so that no air leaks from the primary gas path222. In the illustrative embodiment, the layering of the different components is located at the joint both outside of the gas path222and within the gas path222. In other embodiments, layering may only be included at the joint outside of the primary gas path222.

In the illustrative embodiment, the radius244of the fillet portion240of the airfoil exterior cover ply234is complementary to a radius266of the airfoil fill body236. Further, the radius264of the fillet portion260of the extension over ply252is also complementary to a radius268of the extension fill body254. In some embodiments, the fill bodies236,254may increase in size and therefore resulting in the fillet portions240,260having a greater radius. In other embodiments, the mount portion258of the extension over ply252may have a greater thickness so that the datum features256may be machined more easily.

The turbine vane212may be manufactured in several ways. One method of manufacture may include inserting the airfoil preform216with the airfoil core tube224, airfoil trailing edge fill body228, and the airfoil cover ply226already formed into an airfoil shaped aperture formed in the platform braid preform218, layering the extension fill body254around the outside of the airfoil footprint at the interface between the platform218and the mount extension220, layering the extension over ply252over the components of the airfoil216extending out of the primary gas path222and the extension fill body254, layering the exterior platform ply248over the extension over ply252, infiltrating the entire component to form an integral single piece turbine vane212. The method may also include machining datum features256in the mount extension220to locate the turbine vane212relative to the support structure214.

A portion of a third vane ring assembly310for use in a gas turbine engine is shown illustratively inFIG. 7. The vane ring assembly310is made up of a plurality of individual turbine vanes312and a support structure314. The turbine vanes312comprise ceramic matrix composite materials and are arranged circumferentially adjacent to one another to form a ring that extends around a central axis. The support structure314, shown diagrammatically in FIG.7, comprises metallic materials and engages a mount extension320included in the turbine vane312to couple the turbine vane312to the support structure314to provide a simply supported load path from an airfoil136of the turbine vane312to the support structure314so that aerodynamic loading of the airfoil316may be directly transmitted from the airfoil316to the support structure314. In some embodiments, the support structure314may be adapted for mounting in a ring or to a turbine case included in the vane ring assembly310.

The turbine vane312includes an airfoil316, inner and outer platforms318, and inner and outer mount extensions320as shown inFIGS. 7-9. The airfoil316is shaped to redirect air moving through a primary gas path322within the gas turbine engine. The platforms318extend circumferentially from the airfoil316at least partway about the central axis to define a boundary of the primary gas path322. In the illustrative embodiment, at least some components of the airfoil316are arranged within an airfoil footprint of the airfoil316arranged in the primary gas path322when the turbine vane312is viewed in a radially-inwardly looking direction toward the central axis. The mount extensions320extend outside the primary gas path322to provide a point of coupling for attaching the turbine vane312to a support structure314.

The mount extension320includes at least some components of the airfoil316that extend through the platform318and out of the primary gas path322so that aerodynamic loading of the airfoil may be directly transmitted from the airfoil316to the support structure314. In the illustrative embodiment, the mount extension20includes an airfoil core tube324included in the airfoil316that extends through the platform18and out of the primary gas path22.

In the illustrative embodiment, the airfoil316, the platforms318, and the mount extensions320come together to form one integral single piece turbine vane312as shown inFIG. 7. The interface between the airfoil316, the platform318, and the mount extension320forms a joint therebetween. The joint is reinforced with several reinforcement layers comprising ceramic matrix composite material that are arranged to form a fillet at the joint outside of the gas path322. The layers and fillet reinforcing the joint between the airfoil316, the platform318, and the mount extension320once assembled are infiltrated with matrix material to create one integral single piece turbine vane with no air leakage between the airfoil316and the platforms318.

The construction of the turbine vane312is shown in the illustrative embodiments ofFIGS. 7-9. The airfoil316includes an airfoil core tube324, an airfoil cover ply326, and an airfoil trailing edge fill body328as shown inFIGS. 7-9. The airfoil core tube324is shaped to form a passageway330that extends radially through the airfoil316. The airfoil cover ply326is arranged around the airfoil core tube324and the airfoil trailing edge fill body328to provide an outer surface of the airfoil316within the primary gas path322. The airfoil cover ply326shields the airfoil core tube324and the airfoil trailing edge fill body328from air moving through the primary gas path322. The airfoil trailing edge fill body328is shaped to form the trailing edge of the airfoil316. In the illustrative embodiment, only the airfoil core tube324extends through the platform318and out of the primary gas path322to provide part of the mount extension320.

In some embodiments, the airfoil cover ply326may be integrated into the platform318by partially extending out of the gas path322and interfacing with the platform panel346and the extension fill body354. In another embodiment, the airfoil cover ply326may replace the extension fill body354and extend further out of the gas path322to interface the fillet portion360of the extension over ply352. The platform panel346may also be shaped to form a portion of the extension fill body354when the airfoil cover ply326interfaces the fillet portion360.

In some embodiments, the airfoil cover ply326may have excess material that extends from the trailing edge of the airfoil316. The excess of material would allow for trailing edge machining operations and improve the aerodynamics of the airfoil316.

The platform318includes platform panel346and a platform ply348as shown inFIGS. 8 and 9. The platform panel346extends circumferentially from the airfoil316at least partway about the central axis to define a boundary of the primary gas path322. The platform ply348is arranged so that if forms a radially facing outer surface of the platform318.

The mount extension320further includes an extension over ply of reinforcement material352, an extension fill body354, and a plurality of datum features356as shown inFIGS. 7-9. The extension over ply352is arranged around at least some of the components of the airfoil316outside of the primary gas path322to provide an outer surface of the mount extension320facing circumferentially relative to the central axis away from the components of the airfoil316outside the primary gas path322. The extension fill body354is arranged around at least some of the components of the airfoil316outside of the primary gas path322at the interface of the platform318and the mount extension320. The plurality of datum features356extend out of the airfoil footprint when the turbine vane312is viewed in a radially-inwardly looking direction toward the central axis. The plurality of datum features356are configured to be machined so as to control location of the turbine vane312relative to the support structure314.

In the illustrative embodiment, the datum features356extend outside of the airfoil footprint when the turbine vane is viewed in a radially-inwardly looking direction toward the central axis and directly engage the support structure314. The direct engagement of the datum features356to the support structure allows for the aerodynamic load to be transferred from the airfoil316to the support structure314.

In the illustrative embodiment, the datum features356have a circular cross-sectional shape when viewed from a side of the turbine vane312. In other embodiments, the datum features356may have other suitable cross-sectional shapes.

In the illustrative embodiment, the extension over ply352is arranged around the airfoil core tube324. In other embodiments, the extension over ply352may be arranged around other components of the airfoil316.

The extension over ply of reinforcement material352includes a mount portion358, a fillet portion360, and a retainer portion362as shown inFIGS. 8 and 9. The mount portion358provides the outer surface of the mount extension320. The fillet portion360extends radially from the mount portion358toward the platform318. The fillet portion360is shaped to provide a radius364at the interface of the platform318and the mount extension320and engages the extension fill body354. The retainer portion362extends circumferentially along a radially facing surface of platform318and is sandwiched radially between the platform panel346and the platform ply348of the platform318.

The layering of the different ply and fill body components348,352,354reinforces and seal the joint between the airfoil316, the platform318, and the mount extension320so that no air leaks from the primary gas path322. In the illustrative embodiment, the layering of the different components is located at the joint outside of the gas path322. In other embodiments, additional layering may be included at the joint within the primary gas path322.

In the illustrative embodiment, the radius364of the fillet portion360of the extension over ply352is complementary to a radius366of the extension fill body354. In some embodiments, the extension fill body354may increase in size and therefore resulting in the fillet portion360of the extension over ply352having a greater radius. In other embodiments, the mount portion358of the extension over ply352may have a greater thickness so that the datum features356may be machined more easily.

The turbine vane312may be manufactured in several ways. One method of manufacture may include inserting the airfoil preform316with the airfoil core tube324, airfoil trailing edge fill body328, and the airfoil cover ply326already formed into an airfoil shaped aperture formed in the platform braid preform318, layering the extension fill body350around the outside of the airfoil footprint at the interface between the platform318and the mount extension320, layering the extension over ply352over the components of the airfoil316extending out of the primary gas path22and the extension fill body50, layering the platform ply348over the extension over ply352, infiltrating the entire component to form an integral single piece turbine vane312. The method may also include machining datum features356in the mount extension320to locate the turbine vane312relative to the support structure314.

A portion of a fourth vane ring assembly410for use in a gas turbine engine is shown illustratively inFIG. 10. The vane ring assembly410is made up of a plurality of individual turbine vanes412and a support structure414. The turbine vanes412comprise ceramic matrix composite materials and are arranged circumferentially adjacent to one another to form a ring that extends around a central axis. The support structure414, shown diagrammatically inFIG. 10, comprises metallic materials and engages a mount extension420included in the turbine vane412to couple the turbine vane412to the support structure414to provide a simply supported load path from an airfoil416of the turbine vane412to the support structure414so that aerodynamic loading of the airfoil416may be directly transmitted from the airfoil416to the support structure414. In some embodiments, the support structure414may be adapted for mounting in a ring or to a turbine case included in the vane ring assembly410.

The turbine vane412includes an airfoil416, inner and outer platforms418, and inner and outer mount extensions420as shown inFIGS. 10-12. The airfoil416is shaped to redirect air moving through a primary gas path422within the gas turbine engine. The platforms418extend circumferentially from the airfoil416at least partway about the central axis to define a boundary of the primary gas path422. In the illustrative embodiment, at least some components of the airfoil416are arranged within an airfoil footprint of the airfoil416arranged in the primary gas path422when the turbine vane412is viewed in a radially-inwardly looking direction toward the central axis. The mount extensions420extend outside the primary gas path422to provide a point of coupling for attaching the turbine vane412to a support structure414.

The mount extension420includes at least some components of the airfoil416that extend through the platform418and out of the primary gas path422so that aerodynamic loading of the airfoil may be directly transmitted from the airfoil416to the support structure414. In the illustrative embodiment, the mount extension420includes an airfoil core tube426included in the airfoil416that extends through the platform418and out of the primary gas path422.

In the illustrative embodiment, the airfoil416, the platforms418, and the mount extensions420come together to form one integral single piece turbine vane412as shown inFIG. 10. The interface between the airfoil416, the platform418, and the mount extension420forms a joint therebetween. The joint is reinforced with several reinforcement layers comprising ceramic matrix composite material that are arranged to form a fillet on either side of the joint. The layers and fillet reinforcing the joint between the airfoil416, the platform418, and the mount extension420once assembled are infiltrated with matrix material to create one integral single piece turbine vane with no air leakage between the airfoil416and the platforms418.

The construction of the turbine vane412is shown in the illustrative embodiments ofFIGS. 10-12. The airfoil416includes an airfoil core tube424, an airfoil cover ply426, and an airfoil trailing edge fill body428as shown inFIGS. 10-12. The airfoil core tube424is shaped to form a passageway430that extends radially through the airfoil416. The airfoil cover ply426is arranged around the airfoil core tube424and the airfoil trailing edge fill body428to provide an outer surface of the airfoil416within the primary gas path422. The airfoil cover ply426shields the airfoil core tube424and the airfoil trailing edge fill body428from air moving through the primary gas path422. The airfoil trailing edge fill body428is shaped to form the trailing edge of the airfoil416. In the illustrative embodiment, only the airfoil core tube424extends through the platform418and out of the primary gas path422to provide part of the mount extension420.

In the illustrative embodiment, the airfoil cover ply426includes an airfoil interior cover ply432and an airfoil exterior cover ply434as shown inFIG. 12. The interior cover ply432is arranged around the airfoil core tube424and the airfoil trailing edge fill body428and extends between the platforms418in the primary gas path422. The exterior cover ply434is arranged around the airfoil core tube424, the airfoil trailing edge fill body428, and the interior cover ply432within the primary gas path422.

The airfoil416further includes an airfoil fill body436as shown inFIGS. 11 and 12. The airfoil fill body436is arranged around at least some of the components of the airfoil416inside of the primary gas path422at the interface of the platform418and the airfoil416. In the illustrative embodiment, the airfoil fill body436is arranged around the airfoil core tube424, the airfoil interior cover ply432, and the airfoil trailing edge fill body428. The airfoil exterior cover ply434engages the airfoil fill body436.

In the illustrative embodiments, the airfoil interior cover ply432includes an airfoil portion438, a fillet portion440, and a retainer portion442as shown inFIG. 12. The airfoil portion438provides the inner surface of the airfoil416interacting with the air moving through the primary gas path422. The fillet portion440extends radially from the airfoil portion438toward the platform418. The fillet portion440is shaped to provide a radius444at the interface of the platform418and the airfoil416and engages the airfoil fill body436. The retainer portion442extends circumferentially along a radially facing surface of platform418.

In some embodiments, the airfoil cover ply426may have excess material that extends from the trailing edge of the airfoil416. The excess of material would allow for trailing edge machining operations and improve the aerodynamics of the airfoil416.

The platform418includes platform panel446, an exterior platform ply448, and an interior platform ply450as shown inFIGS. 11 and 12. The platform panel446extends circumferentially from the airfoil416at least partway about the central axis to define a boundary of the primary gas path422. The exterior platform ply448is arranged so that it forms a radially facing outer surface of the platform418. The interior platform ply450is arranged so that it forms a radially facing inner surface of the platform418.

The mount extension420further includes an extension over ply of reinforcement material452, an extension fill body454, and a plurality of datum features456as shown inFIGS. 10-12. The extension over ply452is arranged around at least some of the components of the airfoil416outside of the primary gas path422to provide an outer surface of the mount extension420facing circumferentially relative to the central axis away from the components of the airfoil416outside the primary gas path422. The extension fill body454is arranged around at least some of the components of the airfoil416outside of the primary gas path422at the interface of the platform418and the mount extension420. The plurality of datum features456extend out of the airfoil footprint when the turbine vane412is viewed in a radially-inwardly looking direction toward the central axis. The plurality of datum features456are configured to be machined so as to control location of the turbine vane412relative to the support structure414.

In the illustrative embodiment, the datum features456extend outside of the airfoil footprint when the turbine vane is viewed in a radially-inwardly looking direction toward the central axis and directly engage the support structure414. The direct engagement of the datum features456to the support structure allows for the aerodynamic load to be transferred from the airfoil416to the support structure414.

In the illustrative embodiment, the datum features456have a circular cross-sectional shape when viewed from a side of the turbine vane412. In other embodiments, the datum features456may have other suitable cross-sectional shapes.

In the illustrative embodiment, the extension over ply452is arranged around the airfoil core tube424extending outside of the primary gas path422. In other embodiments, the extension over ply252may be arranged around other components of the airfoil416.

The extension over ply of reinforcement material452includes a mount portion458, a fillet portion460, and a retainer portion462as shown inFIGS. 11 and 12. The mount portion458provides the outer surface of the mount extension420. The fillet portion460extends radially from the mount portion458toward the platform418. The fillet portion460is shaped to provide a radius464at the interface of the platform418and the mount extension420and engages the extension fill body454. The retainer portion462extends circumferentially along a radially facing surface of platform418and is sandwiched radially between the platform panel446and the exterior platform ply448of the platform418.

In the illustrative embodiment, the retainer portion442of the airfoil exterior cover ply434is sandwiched radially between the platform panel446and the interior platform ply450. The layering of the different ply and fill body components432,434,436,448,450,452,454reinforces and seal the joint between the airfoil416, the platform418, and the mount extension420so that no air leaks from the primary gas path422. In the illustrative embodiment, the layering of the different components is located at the joint both outside of the gas path422and within the gas path422. In other embodiments, layering may only be included at the joint outside of the primary gas path422.

In the illustrative embodiment, the radius444of the fillet portion440of the airfoil exterior cover ply434is complementary to a radius466of the airfoil fill body436. Further, the radius464of the fillet portion460of the extension over ply452is also complementary to a radius468of the extension fill body454. In some embodiments, the fill bodies436,454may increase in size and therefore resulting in the fillet portions440,460having a greater radius. In other embodiments, the mount portion458of the extension over ply452may have a greater thickness so that the datum features456may be machined more easily.

The turbine vane412may be manufactured in several ways. One method of manufacture may include inserting the airfoil preform416with the airfoil core tube424, airfoil trailing edge fill body428, and the airfoil cover ply426already formed into an airfoil shaped aperture formed in the platform braid preform418, layering the extension fill body454around the outside of the airfoil footprint at the interface between the platform418and the mount extension420, layering the extension over ply452over the components of the airfoil416extending out of the primary gas path422and the extension fill body454, layering the exterior platform ply448over the extension over ply452, infiltrating the entire component to form an integral single piece turbine vane412. The method may also include machining datum features456in the mount extension420to locate the turbine vane412relative to the support structure414.

Other methods of manufacture could include a two dimensional layup of the platform around the airfoil preform. Another method of manufacture may include fitting the airfoil preform through the platform preform with an airfoil shaped hole to receive the airfoil preform. Another method could include three dimensionally weaving the vane to produce a single integral structure. Another method of manufacture could include creating the airfoil preform from abutted pressure side and suction side preforms. Any combination of these different methods may also be used to manufacture the turbine vane disclosed.

The manufacture of an integrated turbine vane as described in the present disclosure may be created by pre-forming an airfoil and then adding separate platform pre-forms. The approach works for both inner and outer platforms and produces a ceramic matrix composite vane component with no leakage between the airfoil and the platforms. The integrated airfoil and platform structure or vane created would be inherently gas tight and eliminates the need to seal. The integrated vane may also be one of a vane doublet or triplet.

The profile of the disclosed ceramic matrix composite turbine vane allows for location features or datum features to be machined on to the vane. The locating features can also increase the required tolerance to achieve the required turbine capacity. In some embodiments, the location feature or datum feature may be thicker in size such that sufficient machining stock to meet the location tolerance and retain sufficient wall thickness.

The location feature(s) can be located in cooler regions of the assembly which may reduce the rate of environmental degradation to the ceramic matrix composite component. Applying the location features at the cooler regions of the assembly may also reduce the chemical interaction between the ceramic matrix composite materials and the metallic support structure.

Further, locating the location feature(s) in cooler regions increases the metallic strength and allows from better control of the stresses and overall weight creating a more optimal design. Additionally, locating the location feature(s) in cooler regions increases the metallic stiffness at the interface resulting in reduced deflection of the ceramic matrix composite and metallic components in the system. This reduction in deflection allow for better control of the turbine throat area and/or capacity over the engine running range which is important for maintaining engine performance.

The components of the airfoil that protrude the platform out of the gas path may be made with an increased thickness from the platform. The increased thickness allows for machined datum features or sealing features to be incorporated in the vane.

The vane may be supported at both the inner and outer platforms. The aerodynamic loading is transmitted through a stiff, simply supported structure which in turn minimizes the stresses imparted in the platform to airfoil joint as the joint is a region of high stress.