CA1146372A - Structure and method of fabricating a metal composite drive shaft - Google Patents
Structure and method of fabricating a metal composite drive shaftInfo
- Publication number
- CA1146372A CA1146372A CA000373994A CA373994A CA1146372A CA 1146372 A CA1146372 A CA 1146372A CA 000373994 A CA000373994 A CA 000373994A CA 373994 A CA373994 A CA 373994A CA 1146372 A CA1146372 A CA 1146372A
- Authority
- CA
- Canada
- Prior art keywords
- turbine engine
- gas turbine
- composite shaft
- high specific
- fabricating
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Expired
Links
Classifications
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F16—ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
- F16C—SHAFTS; FLEXIBLE SHAFTS; ELEMENTS OR CRANKSHAFT MECHANISMS; ROTARY BODIES OTHER THAN GEARING ELEMENTS; BEARINGS
- F16C3/00—Shafts; Axles; Cranks; Eccentrics
- F16C3/02—Shafts; Axles
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F16—ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
- F16C—SHAFTS; FLEXIBLE SHAFTS; ELEMENTS OR CRANKSHAFT MECHANISMS; ROTARY BODIES OTHER THAN GEARING ELEMENTS; BEARINGS
- F16C2360/00—Engines or pumps
- F16C2360/23—Gas turbine engines
Landscapes
- Engineering & Computer Science (AREA)
- General Engineering & Computer Science (AREA)
- Ocean & Marine Engineering (AREA)
- Mechanical Engineering (AREA)
- Laminated Bodies (AREA)
- Shafts, Cranks, Connecting Bars, And Related Bearings (AREA)
- Turbine Rotor Nozzle Sealing (AREA)
- Pressure Welding/Diffusion-Bonding (AREA)
Abstract
ABSTRACT OF THE DISCLOSURE
A high specific modulus shaft for a gas turbine engine is constructed having a metal outer tube to trans-mit the torque and a metal and high modulus filament com-posite sleeve bonded to the tube's inner diameter. The composite sleeve is fabricated and bonded to the inner diameter of the tube by winding the composite composition tape on a mandrel with the filaments axially aligned. The mandrel is then inserted into a metal outer tube. The as-sembly is encapsulated, evacuated and sealed and the man-drel pressurized at a sufficient temperature to achieve consolidation and diffusion bonding of the wound composite to itself and the shaft inner diameter.
A high specific modulus shaft for a gas turbine engine is constructed having a metal outer tube to trans-mit the torque and a metal and high modulus filament com-posite sleeve bonded to the tube's inner diameter. The composite sleeve is fabricated and bonded to the inner diameter of the tube by winding the composite composition tape on a mandrel with the filaments axially aligned. The mandrel is then inserted into a metal outer tube. The as-sembly is encapsulated, evacuated and sealed and the man-drel pressurized at a sufficient temperature to achieve consolidation and diffusion bonding of the wound composite to itself and the shaft inner diameter.
Description
11463'~;~
STRUCTURE AND METHOD OF FABRICATING
A METAL COMPOSITE DRIVE SHAFT
Background of the Invention One persistent trend in the gas turbine industry is the development of smaller, more efficient engines with in-creased specific power. These changes invariably result in correspondingly higher speed and stress levels on the prin-cipal engine components. An engine drive or power shaft is a prime example of this condition since the combination of increased rotor speed and smaller shaft diameter create critical speed problems. One solution is to decrease the effective shaft length by adding additional bearing sup-ports. This creates added mechanical complexities to achieving and assemblying a smaller engine. A simplier and more practical ~olution to the problem is to construct shafts with higher modulus to density ratio which will re-sult in an increased specific stiffr.ess and critical speed.
Summary of the Invention A combined metal and composite shaft i5 constructed to withstand the torsional and bending ~tresses placed on a small diameter drive shaft for a gas turbine engine.
First, an outer tubular steel shaft is constructed. Then boron filaments are carefully positioned and spaced between two thin film layers of aluminum to form an aluminum sheet having interior longitudinally oriented boron filaments.
The boron/aluminum sheet is rolled onto a mild steel man-drel and inserted into the tubular steel shaft with the filaments aligned axially. The assembly is placed in an autoclave which is first pressurized to 4 - 5 ksi, heated to 960 F and then subjected to an increased pressure of 10 ks~ for a half hour. This process results in a fully i~
1~6372 consolidated composite shaft having a steel outer shell and an aluminum inner sleeve reinforced by axially aligned boron filaments to enhance bending stiffness.
Description of the Drawing This invention is described in more detail below with reference to the drawing in which:
Figure 1 is a perspective view of one end of the fab-ricated shaft; and Figure 2 is a sectional view taken along a longitudi-nal plane through the axis.
Detailed Descri~tion of_the Preferred Embodiment A completed shaft 1 constructed according to this in-vention is shown in Figures 1 and 2 and consists of a hard-ened steel tubular outer shaft 2 including hardened spline 6 to which is bounded on its inner diameter a high speci-fic modulus layer 3. The layer 3 as best seen in Figure 2 consists of a fully consolidated aluminum matrix in which multiple boron filaments 4 are imbedded in general align-ment with axis S.
The layer 3 consists of 7 mil thick aluminum matrix tape with 5.6 mil boron filaments sandwiched inside. A
titanium tape could al~o be used, but in that instance silicon carbide or boron carbide coated boron filaments should be used to prevent interaction between the titanium and boron.
The layer 3 i8 rolled onto a mild steel mandrel and i~
inserted into the tubular steel shaft 2. This assembly is then placed into an autoclave in which the pressure is then raised to an intermediate pre~ure of 4 to 5 ksi. By raising the *emperature at this point to 960~ F the duct-ility of the layer 3 and its mandrel are increased to fac-ilitate the initial stages of bonding. As a final step, the pressure is then elevated to 10 ksi and held for ap-proximately a half hour to allow complete consolidation.
35 The mandrel is then removed through a chemical milling process.
The turbine shaft 2 can be constructed of either steel or titanium to insure torsional integrity of the composite shaft. A typical shaft 1 could have a steel or titanium i372 outer sheath having an outside diameter of 1 inch and an interior diameter of .625 inch with a .070 inch thick boron/aluminum layer 3 bonded at the interior diameter.
In this manner a composite shaft is constructed hav-ing a high specific modulus which provides a greatercritical speed~ Since the outer surface is constructed of steel, it may be machined or welded as required.
To avoid the use of an autoclave, the assembly of the shaft and mandrel may be sealed and evacuated. The assembly could then be pressurized through an internal axial passage within the mandrel. By pressurizing under high temperature consolidation and diffusion, bonding of the tape and the tape to the shaft can be assured.
STRUCTURE AND METHOD OF FABRICATING
A METAL COMPOSITE DRIVE SHAFT
Background of the Invention One persistent trend in the gas turbine industry is the development of smaller, more efficient engines with in-creased specific power. These changes invariably result in correspondingly higher speed and stress levels on the prin-cipal engine components. An engine drive or power shaft is a prime example of this condition since the combination of increased rotor speed and smaller shaft diameter create critical speed problems. One solution is to decrease the effective shaft length by adding additional bearing sup-ports. This creates added mechanical complexities to achieving and assemblying a smaller engine. A simplier and more practical ~olution to the problem is to construct shafts with higher modulus to density ratio which will re-sult in an increased specific stiffr.ess and critical speed.
Summary of the Invention A combined metal and composite shaft i5 constructed to withstand the torsional and bending ~tresses placed on a small diameter drive shaft for a gas turbine engine.
First, an outer tubular steel shaft is constructed. Then boron filaments are carefully positioned and spaced between two thin film layers of aluminum to form an aluminum sheet having interior longitudinally oriented boron filaments.
The boron/aluminum sheet is rolled onto a mild steel man-drel and inserted into the tubular steel shaft with the filaments aligned axially. The assembly is placed in an autoclave which is first pressurized to 4 - 5 ksi, heated to 960 F and then subjected to an increased pressure of 10 ks~ for a half hour. This process results in a fully i~
1~6372 consolidated composite shaft having a steel outer shell and an aluminum inner sleeve reinforced by axially aligned boron filaments to enhance bending stiffness.
Description of the Drawing This invention is described in more detail below with reference to the drawing in which:
Figure 1 is a perspective view of one end of the fab-ricated shaft; and Figure 2 is a sectional view taken along a longitudi-nal plane through the axis.
Detailed Descri~tion of_the Preferred Embodiment A completed shaft 1 constructed according to this in-vention is shown in Figures 1 and 2 and consists of a hard-ened steel tubular outer shaft 2 including hardened spline 6 to which is bounded on its inner diameter a high speci-fic modulus layer 3. The layer 3 as best seen in Figure 2 consists of a fully consolidated aluminum matrix in which multiple boron filaments 4 are imbedded in general align-ment with axis S.
The layer 3 consists of 7 mil thick aluminum matrix tape with 5.6 mil boron filaments sandwiched inside. A
titanium tape could al~o be used, but in that instance silicon carbide or boron carbide coated boron filaments should be used to prevent interaction between the titanium and boron.
The layer 3 i8 rolled onto a mild steel mandrel and i~
inserted into the tubular steel shaft 2. This assembly is then placed into an autoclave in which the pressure is then raised to an intermediate pre~ure of 4 to 5 ksi. By raising the *emperature at this point to 960~ F the duct-ility of the layer 3 and its mandrel are increased to fac-ilitate the initial stages of bonding. As a final step, the pressure is then elevated to 10 ksi and held for ap-proximately a half hour to allow complete consolidation.
35 The mandrel is then removed through a chemical milling process.
The turbine shaft 2 can be constructed of either steel or titanium to insure torsional integrity of the composite shaft. A typical shaft 1 could have a steel or titanium i372 outer sheath having an outside diameter of 1 inch and an interior diameter of .625 inch with a .070 inch thick boron/aluminum layer 3 bonded at the interior diameter.
In this manner a composite shaft is constructed hav-ing a high specific modulus which provides a greatercritical speed~ Since the outer surface is constructed of steel, it may be machined or welded as required.
To avoid the use of an autoclave, the assembly of the shaft and mandrel may be sealed and evacuated. The assembly could then be pressurized through an internal axial passage within the mandrel. By pressurizing under high temperature consolidation and diffusion, bonding of the tape and the tape to the shaft can be assured.
Claims (13)
PROPERTY OR PRIVILEGE IS CLAIMED ARE DEFINED AS FOLLOWS:
1. A composite shaft for a gas turbine engine having a high specific modulus comprising:
an outer tubular sheath constructed of machinable high torsion resistant material and having an interior axially extending passage; and an interior shell constructed of a metal matrix containing axially aligned filaments of a high modu-lus material, said shell being completely consolidated and bonded on the inner diameter of the tubular sheath
an outer tubular sheath constructed of machinable high torsion resistant material and having an interior axially extending passage; and an interior shell constructed of a metal matrix containing axially aligned filaments of a high modu-lus material, said shell being completely consolidated and bonded on the inner diameter of the tubular sheath
2. A composite shaft for a gas turbine engine having a high specific modulus as described in claim 1 wherein the tubular sheath is constructed of steel.
3. A composite shaft for a gas turbine engine having a high specific modulus as described in claim 1 wherein the tubular sheath is constructed of titanium.
4. A composite shaft for a gas turbine engine having a high specific modulus as described in claim 1 wherein the metal matrix is aluminum.
5. A composite shaft for a gas turbine engine having a high specific modulus as described in claim 1 wherein the metal matrix is titanium.
6. A composite shaft for a gas turbine engine having a high specific modulus as described in claim 1 wherein the high modulus material is boron.
7. A method of fabricating a composite shaft for a gas turbine engine having a high specific modulus compris-ing the steps of:
constructing an outer tubular sheath of machinable high torsion resistant material and having an interior axially extending passage;
constructing a metal matrix tape having longitud-inally extending high modulus material filaments im-bedded therein;
rolling the matrix tape on a mandrel with the high modulus filaments oriented in an axial direction;
inserting the tape and mandrel into the axially extending passage in close contact with the inner di-ameter of the tubular sheath; and subjecting said assembly to sufficient temperature and pressure to achieve consolidation and diffusion bonding of the filament reinforced metal tape into the outer tubular sheath.
constructing an outer tubular sheath of machinable high torsion resistant material and having an interior axially extending passage;
constructing a metal matrix tape having longitud-inally extending high modulus material filaments im-bedded therein;
rolling the matrix tape on a mandrel with the high modulus filaments oriented in an axial direction;
inserting the tape and mandrel into the axially extending passage in close contact with the inner di-ameter of the tubular sheath; and subjecting said assembly to sufficient temperature and pressure to achieve consolidation and diffusion bonding of the filament reinforced metal tape into the outer tubular sheath.
8. A method of fabricating a composite shaft for a gas turbine engine as described in claim 7 wherein consoli-dation is achieved by:
placing said assembly in an autoclave;
raising the pressure in said autoclave to an in-termediate level;
increasing the temperature in said autoclave to a temperature which increases the ductility of the man-drel and film and promotes bonding; and further raising the pressure in the autoclave to promote bonding and consolidation and holding said pressure until said processes are complete.
placing said assembly in an autoclave;
raising the pressure in said autoclave to an in-termediate level;
increasing the temperature in said autoclave to a temperature which increases the ductility of the man-drel and film and promotes bonding; and further raising the pressure in the autoclave to promote bonding and consolidation and holding said pressure until said processes are complete.
9. A method of fabricating a composite shaft for a gas turbine engine having a high specific modulus as de-scribed in claim 7 wherein the outer tubular sheath is constructed of steel.
10. A method of fabricating a composite shaft for a gas turbine engine having a high specific modulus as de-scribed in claim 7 wherein the outer tubular sheath is con-structed of titanium.
11. A method of fabricating a composite shaft for a gas-turbine engine having a high specific modulus as de-scribed in claim 7 wherein the metal matrix tape is formed by sandwiching the longitudinally aligned filaments between two thin films of metal.
12. A method of fabricating a composite shaft for a gas turbine engine as described in claim 8 wherein the metal matrix is constructed of aluminum.
13. A method of fabricating a composite shaft for a gas turbine engine as described in claim 12 wherein the high modulus filaments are constructed of boron.
Applications Claiming Priority (2)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| US16303780A | 1980-06-26 | 1980-06-26 | |
| US163,037 | 1980-06-26 |
Publications (1)
| Publication Number | Publication Date |
|---|---|
| CA1146372A true CA1146372A (en) | 1983-05-17 |
Family
ID=22588199
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CA000373994A Expired CA1146372A (en) | 1980-06-26 | 1981-03-27 | Structure and method of fabricating a metal composite drive shaft |
Country Status (8)
| Country | Link |
|---|---|
| JP (1) | JPS5715114A (en) |
| BR (1) | BR8103330A (en) |
| CA (1) | CA1146372A (en) |
| DE (1) | DE3108318A1 (en) |
| FR (1) | FR2485659A1 (en) |
| GB (1) | GB2078338B (en) |
| IT (1) | IT1137947B (en) |
| SE (1) | SE8101237L (en) |
Families Citing this family (8)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| DE3800913A1 (en) * | 1988-01-14 | 1989-08-03 | Emitec Emissionstechnologie | MULTI-LAYER DRIVE SHAFT |
| GB2220595B (en) * | 1988-07-13 | 1992-10-21 | Secr Defence | Hard surface composite parts. |
| GB2247492B (en) * | 1990-09-01 | 1995-01-11 | Rolls Royce Plc | A method of making a fibre reinforced metal component |
| US5305520A (en) * | 1990-09-01 | 1994-04-26 | Rolls-Royce Plc | Method of making fibre reinforced metal component |
| US8225481B2 (en) * | 2003-05-19 | 2012-07-24 | Pratt & Whitney Rocketdyne, Inc. | Diffusion bonded composite material and method therefor |
| US6897578B1 (en) * | 2003-12-08 | 2005-05-24 | Ingersoll-Rand Energy Systems Corporation | Integrated microturbine gearbox generator assembly |
| GB2438633B (en) * | 2006-05-31 | 2010-12-01 | Tisics Ltd | Reinforced splines and their manufacture |
| US20080148708A1 (en) | 2006-12-20 | 2008-06-26 | General Electric Company | Turbine engine system with shafts for improved weight and vibration characteristic |
Family Cites Families (5)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| FR1548099A (en) * | 1966-12-22 | 1968-11-29 | ||
| DE1750523B1 (en) * | 1968-05-10 | 1971-12-09 | Augsburg Nuernberg Ag Zweignie | METHOD OF MANUFACTURING A DRUM OR SHAFT |
| US3651661A (en) * | 1970-02-02 | 1972-03-28 | United Aircraft Corp | Composite shaft with integral end flange |
| CA1098329A (en) * | 1977-12-02 | 1981-03-31 | Richard L. Vanauken | Composite tubular element and methods for making same |
| US4272971A (en) * | 1979-02-26 | 1981-06-16 | Rockwell International Corporation | Reinforced tubular structure |
-
1981
- 1981-02-25 SE SE8101237A patent/SE8101237L/en not_active Application Discontinuation
- 1981-03-02 GB GB8106563A patent/GB2078338B/en not_active Expired
- 1981-03-02 DE DE19813108318 patent/DE3108318A1/en not_active Withdrawn
- 1981-03-17 JP JP3733781A patent/JPS5715114A/en active Pending
- 1981-03-27 CA CA000373994A patent/CA1146372A/en not_active Expired
- 1981-04-23 FR FR8108090A patent/FR2485659A1/en active Granted
- 1981-05-28 BR BR8103330A patent/BR8103330A/en unknown
- 1981-06-26 IT IT22601/81A patent/IT1137947B/en active
Also Published As
| Publication number | Publication date |
|---|---|
| JPS5715114A (en) | 1982-01-26 |
| IT8122601A0 (en) | 1981-06-26 |
| DE3108318A1 (en) | 1982-01-21 |
| SE8101237L (en) | 1981-12-27 |
| FR2485659A1 (en) | 1981-12-31 |
| GB2078338B (en) | 1983-08-10 |
| FR2485659B1 (en) | 1984-12-28 |
| GB2078338A (en) | 1982-01-06 |
| IT1137947B (en) | 1986-09-10 |
| BR8103330A (en) | 1982-02-16 |
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Legal Events
| Date | Code | Title | Description |
|---|---|---|---|
| MKEX | Expiry |