In the context of the energy transition towards circular energy management, improving fan impeller performance is crucial, e.g. in heat pumps in an industrial context. The high specific strength of carbon fibre reinforced polymers (CFRP) enables composite impellers to achieve higher circumferential speeds, leading to improved efficiency in various energy applications compared to conventional metal designs.
This study focuses on optimizing the design and manufacturing methods of modular composite centrifugal impellers to maximize both structural integrity and aerodynamic performance. Three distinct impeller designs were developed, each tailored to meet specific requirements in terms of manufacturing effort, quality and structural robustness. Preliminary studies on two different manufacturing methods were carried out: Tailored Fibre Placement (TFP) and patch-layup. TFP allows a precise fibre placement along load paths, while patch laminates allow for simpler design and manufacturing. Numerical analysis was conducted to compare the structural performance of the resulting designs, particularly focusing on a carrier disc. Additionally, the study extends to experimentally investigating interface connections between composite discs and blades. This includes examining adhesive joints with and without additional metallic fasteners.
Overall, this research contributes to advancing the understanding of composite centrifugal impeller design and manufacturing, paving the way for more efficient and sustainable energy applications.