The article describes the development of stator guide vanes made of thermoplastic composites for aircraft engines, which replace conventional metallic guide vanes in the air flow path. Guide vanes are stationary aerodynamic components that guide the air flow through the compressor and turbine stages of a jet engine.
In conventional designs, these components are typically made from metallic alloys due to their strength and durability. However, increasing pressure to improve fuel efficiency and reduce aircraft weight means that engineers are increasingly investigating advanced composite solutions.
The newly developed thermoplastic vanes are aimed in particular at static, non-rotating blades in smaller business jet engines. Replacing metallic components with composite structures can significantly improve the overall efficiency of the engine.
Source: Greene Tweed - Xycomp DLF guide vanes
The technology
The solution developed by Greene Tweed is based on a thermoplastic composite material called Xycomp DLF (Discontinuous Long Fiber). This consists of cut, aerospace-grade carbon fiber prepreg tapes embedded in high-performance thermoplastics such as PEEK, PEKK or PEI.
These materials are pressed into aerodynamic blade geometries close to the final contour („near-net-shape“) using a proprietary process.
A key technological innovation is the integration of a co-molded metallic leading edge that is mechanically interlocked with the composite structure. This significantly improves resistance to the effects of foreign bodies such as hail or particles.
The thermoplastic production process also enables a single-stage shaping process with short cycle times. This enables efficient series production while meeting high aviation performance requirements.
The lightweight construction aspect
The replacement of conventional metallic stator guide vanes with thermoplastic composite components leads to a significant reduction in weight while at the same time meeting mechanical and aerodynamic requirements.
The solution developed enables a weight saving of around 4 kg per engine, with around 60 guide vanes per engine assembly - a significant contribution to system weight reduction.
In addition to weight reduction, thermoplastic composites offer further advantages such as high impact strength, short production cycles and improved scalability in production - decisive factors for applications in aviation.
These properties make thermoplastic composites an attractive solution for future engine components and underline their potential to enable lighter and more efficient propulsion systems in aviation.
Deutsch 
English