Method for manufacturing a cooling assembly for a turbine part

Abstract

A method of forming a cooling assembly in a turbine part is provided. The method includes partially placing a packaged diffuser insert in a bore of the turbine part. The packaged diffuser insert has an unobstructed central passage having a generally circular cross-section at a first end and an elongated rectangular cross-section at a second end opposite the first end. The second end has a sacrificial cap. A coating step coats the turbine part to at least partially package the packaged diffuser insert in a coating. A removal step removes the sacrificial cap to allow air flow through the central passage. The packaged diffuser insert remains in the bore of the turbine part and the coating, providing an unobstructed central passage having a generally circular first end and an elongated rectangular second end adjacent an outer surface of the turbine part.

Description

Technical Field

[0001] The subject matter described in this article relates to methods for fabricating cooling components, and more specifically, to methods for encapsulating diffusion cooling components within a thermal barrier coating of turbine parts. Background Technology

[0002] Turbines experience increased thermal loads during engine operation. To protect the turbine from damage, cooling fluid can be directed into and / or onto the turbine components. Component temperature can then be managed through a combination of impact on the components, cooling flow through channels in the components, and film cooling, balancing the goals of component life and turbine efficiency. Improved efficiency can be achieved by increasing ignition temperature, reducing cooling flow, or a combination thereof.

[0003] One problem with cooling known turbine components is insufficient refrigerant coverage on their surfaces. Insufficient refrigerant coverage can cause average and / or localized turbine component surface temperatures to remain excessively high, increasing the overall heat load on the turbine and potentially reducing component life to below acceptable levels or requiring additional cooling fluid. Therefore, improved systems provide improved cooling coverage and thus reduce coverage and / or localized surface temperatures in critical parts of the turbine assembly, allowing the engine to operate more efficiently and / or improving turbine life. Summary of the Invention

[0004] In one aspect, a method of forming a cooling assembly in a turbine component is provided. The method includes partially placing an encapsulated diffuser insert into an aperture in the turbine component. The encapsulated diffuser insert has an unobstructed central channel having a generally circular cross-section at a first end and an elongated rectangular cross-section at a second end opposite to the first end. The second end has a sacrificial cap. A coating step coats the turbine component to at least partially encapsulate the encapsulated diffuser insert in the coating. A removal step removes the sacrificial cap to allow airflow through the central channel. The encapsulated diffuser insert remains in the aperture and coating of the turbine component, thereby providing an unobstructed central channel having a generally circular first end and an elongated rectangular second end adjacent to an outer surface of the turbine component.

[0005] In another aspect, a method is provided for forming a cooling assembly in a turbine component. The method includes partially placing an encapsulated diffuser insert into an aperture in the turbine component. The encapsulated diffuser insert has an unobstructed central channel having a generally circular cross-section at a first end and an elongated rectangular cross-section at a second end opposite the first end. The second end has a sacrificial cap. A coating step is used to coat the turbine component with a thermal barrier coating to at least partially encapsulate the encapsulated diffuser insert within the thermal barrier coating. A removal step removes the sacrificial cap to open and allow airflow through the central channel. The encapsulated diffuser insert remains in the aperture and coating of the turbine component, thereby providing an unobstructed central channel having a generally circular first end and an elongated rectangular second end adjacent to the outer surface of the turbine component. The turbine component is a blade, guide vane, or nozzle.

[0006] In another aspect, a method for forming a cooling assembly in a turbine component is provided. The method includes a placement step for partially placing an encapsulated diffuser insert into a bore in the turbine component. The encapsulated diffuser insert has an unobstructed central channel having a generally circular cross-section at a first end and an elongated rectangular cross-section at a second end opposite to the first end. The second end has a sacrificial cap. The sacrificial cap has a cap guide formed in a curved path or a path having one or more inflections. A securing step secures the encapsulated diffuser insert in the bore by at least one of the following: friction fit, welding, adhesive bonding, or mechanical locking. A coating step applies a protective coating to the turbine component to at least partially encapsulate the encapsulated diffuser insert within the protective coating. A removal step removes the sacrificial cap to allow airflow through the central channel. The encapsulated diffuser insert remains in the bore of the turbine component and the protective coating, thereby providing an unobstructed central channel having a generally circular first end and an elongated rectangular second end adjacent to the outer surface of the turbine component.

[0007] Technical Solution 1. A method for forming a cooling assembly in a turbine component, the method comprising:

[0008] The encapsulated diffuser insert is partially placed into a hole in the turbine component, the encapsulated diffuser insert having an unobstructed central channel having a generally circular cross-section at a first end and an elongated rectangular cross-section at a second end opposite to the first end, the second end having a sacrificial cap;

[0009] The turbine parts are coated to at least partially encapsulate the packaged diffuser insert within the coating.

[0010] The sacrificial cap is removed to allow airflow through the central channel, wherein the encapsulated diffuser insert remains in the hole and the coating of the turbine component, thereby providing the unobstructed central channel having a generally circular first end and an elongated rectangular second end adjacent to the outer surface of the turbine component.

[0011] Technical Solution 2. According to the method of Technical Solution 1, the first end has a first diameter of the generally circular cross-section, and the second end has a second width and a second length of the elongated rectangular cross-section; and

[0012] The second width is approximately half the diameter of the first diameter, and the second length is approximately one and a half times the diameter of the first diameter.

[0013] Technical Solution 3. According to the method of Technical Solution 1, the first end has a first diameter of the generally circular cross-section, and the second end has a second width and a second length of the elongated rectangular cross-section; and

[0014] Wherein, the second width is equal to or less than half of the first diameter, and the second length is equal to or greater than 1.5 times the first diameter.

[0015] Technical Solution 4. The method according to Technical Solution 1, wherein the area of ​​the first end is approximately equal to the area of ​​the second end.

[0016] Technical Solution 5. The method according to Technical Solution 1, wherein the area of ​​the first end is not equal to the area of ​​the second end.

[0017] Technical Solution 6. The method according to Technical Solution 1 further includes:

[0018] Prior to the placement step, the diffuser insert of the package is formed by at least one of the following: brazing, additive manufacturing, extrusion, and machining.

[0019] Technical Solution 7. The method according to Technical Solution 1, wherein the unobstructed central channel of the encapsulated diffuser insert is a completely unobstructed channel with a diffusion outlet.

[0020] Technical Solution 8. According to the method of Technical Solution 1, the placement step further includes:

[0021] The packaged diffuser insert is secured in the hole by at least one of the following: friction fit, welding, adhesive bonding, or mechanical locking.

[0022] Technical Solution 9. According to the method of Technical Solution 1, the coating step further includes:

[0023] The turbine parts are coated with a thermal barrier coating.

[0024] Technical Solution 10. The method according to Technical Solution 1, wherein the turbine component is a blade, guide vane, or nozzle.

[0025] Technical Solution 11. The method according to Technical Solution 1, wherein the sacrificial cap comprises a cap conduit formed in a curved path or a path having one or more inflection points.

[0026] Technical Solution 12. A method for forming a cooling assembly in a turbine component, the method comprising:

[0027] The encapsulated diffuser insert is partially placed into a hole in the turbine component, the encapsulated diffuser insert having an unobstructed central channel having a generally circular cross-section at a first end and an elongated rectangular cross-section at a second end opposite to the first end, the second end having a sacrificial cap;

[0028] The turbine parts are coated with a thermal barrier coating to at least partially encapsulate the encapsulated diffuser insert within the thermal barrier coating;

[0029] The sacrificial cap is removed to allow airflow through the central channel, the encapsulated diffuser insert remaining in the orifice and thermal barrier coating of the turbine component, thereby providing the unobstructed central channel having a generally circular first end and an elongated rectangular second end adjacent to the outer surface of the turbine component, wherein the turbine component is a blade, guide vane, or nozzle.

[0030] Technical Solution 13. According to the method of Technical Solution 12, the first end has a first diameter of the generally circular cross section, and the second end has a second width and a second length of the elongated rectangular cross section;

[0031] The second width is approximately half the first diameter, and the second length is approximately 1.5 times the first diameter; or

[0032] The second width is equal to or less than half the first diameter, and the second length is equal to or greater than 1.5 times the first diameter.

[0033] Technical Solution 14. The method according to Technical Solution 13, wherein the area of ​​the first end is approximately equal to the area of ​​the second end, or the area of ​​the first end is not equal to the area of ​​the second end.

[0034] Technical solution 15. The method according to technical solution 12 further includes:

[0035] Prior to the placement step, the diffuser insert of the package is formed by at least one of the following: brazing, additive manufacturing, extrusion, and machining.

[0036] Technical Solution 16. The method according to Technical Solution 12, wherein the placement step further includes:

[0037] The packaged diffuser insert is secured in the hole by at least one of the following: friction fit, welding, adhesive bonding, or mechanical locking.

[0038] Technical Solution 17. The method according to Technical Solution 12, wherein the sacrificial cap comprises a cap conduit formed in a curved path or a path having one or more inflection points.

[0039] Technical Solution 18. A method for forming a cooling assembly in a turbine component, the method comprising:

[0040] The encapsulated diffuser insert is partially placed into a hole in the turbine component. The encapsulated diffuser insert has an unobstructed central channel with a generally circular cross-section at a first end and an elongated rectangular cross-section at a second end opposite to the first end. The second end has a sacrificial cap with a cap conduit formed in a curved path or a path with one or more inflection points.

[0041] The packaged diffuser insert is secured in the hole by at least one of the following: friction fit, welding, adhesive bonding or mechanical locking;

[0042] The turbine parts are coated with a protective coating to at least partially encapsulate the packaged diffuser insert within the protective coating;

[0043] The sacrificial cap is removed to allow airflow through the central channel, and the encapsulated diffuser insert remains in the hole and the protective coating of the turbine component, thereby providing the unobstructed central channel having a generally circular first end and an elongated rectangular second end adjacent to the outer surface of the turbine component.

[0044] Technical Solution 19. The method according to Technical Solution 18, wherein the first end has a first diameter of the generally circular cross section, and the second end has a second width and a second length of the elongated rectangular cross section;

[0045] The second width is approximately half the first diameter, and the second length is approximately 1.5 times the first diameter; or

[0046] The second width is equal to or less than half the first diameter, and the second length is equal to or greater than 1.5 times the first diameter.

[0047] Technical Solution 20. The method according to Technical Solution 19, wherein the area of ​​the first end is approximately equal to the area of ​​the second end, or the area of ​​the first end is not equal to the area of ​​the second end. Attached Figure Description

[0048] The subject matter of the invention will be better understood by referring to the following description of non-limiting aspects / embodiments, as shown in the accompanying drawings:

[0049] Figure 1 An example of a turbine assembly based on one aspect is shown.

[0050] Figure 2 A cross-sectional view of a known cooling component is shown.

[0051] Figure 3 A top view of the outer surface of a turbine component having a cooling air outlet with an elongated rectangular cross-section, according to an aspect of this disclosure, is shown.

[0052] Figure 4 A top view of the outer surface of a turbine component having a cooling air outlet with an elongated rectangular cross-section, according to an aspect of this disclosure, is illustrated.

[0053] Figure 5 The first (or placement) step in a method of forming a cooling assembly according to aspects of this disclosure is illustrated.

[0054] Figure 6 The second (or coating) step in a method of applying a coating to the outer surface of a turbine component, according to aspects of this disclosure, is illustrated.

[0055] Figure 7 An example is given of a third (or removal) step in accordance with an aspect of this disclosure, in which the sacrificial cap is removed.

[0056] Figure 8 This is a flowchart of a method for forming a cooling assembly in a turbine component, according to aspects of this disclosure.

[0057] Figure 9 An enlarged cross-sectional view of a portion of an encapsulated diffuser insert is shown, wherein the sacrificial cap has a cap conduit formed in a path having one or more inflection points.

[0058] Figure 10 An enlarged cross-sectional view of a portion of the packaged diffuser insert is shown, wherein the sacrificial cap has a cap conduit formed in a curved path.

[0059] Figure 11 A cross-sectional view of a diffuser insert shown as a package mechanically locked in a hole in a part is illustrated. Detailed Implementation

[0060] Figure 1 An example of a known turbine or turbine 10 is shown. Turbine 10 includes an inlet 16 through which air enters turbine 10 in the direction of arrow 50. The air travels along direction 50 from inlet 16, through compressor 18, through burner 20, and through turbine 22 to outlet 24. Rotating shaft 26 extends through and is coupled to one or more rotating components of turbine 10, and may be coupled to a load (not shown), such as a generator.

[0061] Compressor 18 and turbine 22 include multiple blades and guide vanes / nozzles. Blade 30 is located in the compressor, and blade 30' is located in the turbine. Guide vanes / nozzles 36 are located in the compressor, and guide vanes / nozzles 36' are located in the turbine. Blades 30, 30' are axially offset from guide vanes 36, 36' along direction 50 (or along the axial direction relative to turbine 10). For example, the axial direction is collinear with the longitudinal centerline of shaft 26. Guide vanes 36, 36' are stationary components, while blades 30, 30' are operatively coupled to shaft 26 and rotate with it.

[0062] Figure 2 Examples are given ( Figure 1 A cross-sectional view of a known cooling assembly 100 of the turbine assembly 10. The cooling assembly 100 operates to aid in cooling the airfoil 104 of the turbine assembly. The airfoil 104 is used in ( Figure 1 The turbine blades in the turbine assembly 10 (e.g., Figure 1 The blades 30, 30'). The airfoil 104 has a pressure side 114 and a suction side 116 opposite to the pressure side 114. The pressure side 114 and the suction side 116 are connected to each other by a leading edge 118 and a trailing edge (not shown) opposite to the leading edge 118. Between the leading and trailing edges of the airfoil 104, the pressure side 114 is generally concave in shape, and the suction side 116 is generally convex in shape. For example, the generally concave pressure side 114 and the generally convex suction side 116 provide an aerodynamic surface above which compressed working fluid flows in direction B through the turbine assembly.

[0063] Airfoil 104 has one or more internal cooling chambers 102a, 102b. As shown, airfoil 104 has two cooling chambers 102a, 102b. Cooling chamber 102 is disposed within the interior of airfoil 104. For example, cooling chamber 102 is completely housed within airfoil 104 between pressure side 114 and suction side 116. Cooling chamber 102 is configured to direct cooling air into airfoil 104 to cool airfoil 104 when turbine assembly is operating.

[0064] Cooling chamber 102a is fluidly connected to conduit or orifice 106. As shown, a conduit 106 fluidly connects cooling chamber 102a to outer surface 108. Conduit 106 is a cylindrical channel with sidewalls 112 disposed between and fluidly connecting cooling chamber 102a and the exterior of airfoil 104. Conduit 106 guides cooling air leaving cooling chamber 102a to the exterior of outer surface 108 in direction A. For example, conduit 106 guides cooling air leaving cooling chamber 102a along the outer surface 108 of airfoil 104 in direction A. Conduit 106 is fluidly connected between cooling chamber 102a and outer surface 108 on the suction side 116 of airfoil 104. A disadvantage of cylindrical orifice / conduit 106 is that cooling air is ejected upwards and away from surface 108. The inlet and outlet of orifice conduit 106 are generally circular in cross-section. The circular shape of the outlet of the orifice / duct 106 is not very efficient in keeping the cooling air close to the surface 108, or in distributing the cooling air evenly along the surface 108. The cooling air is rapidly ejected upward from the outlet and travels along a narrow path along the surface 108, thus limiting the efficiency of the cooling air.

[0065] Figure 3 and Figure 4 A top view of the outer surface 301 of a turbine component 300 according to an aspect of this disclosure is illustrated. The turbine component 300 may be a blade (e.g., similar to...). Figure 1 Blades 30, 30'), guide vanes / nozzles (e.g., similar to...) Figure 1 The guide vanes / nozzles 36, 36'), combustion bushings, or any other turbine parts requiring cooling. The outer or external surface 301 of the part (similar to...) Figure 2 The surface 108 has a rectangular (not square) opening (or second end) 310 that functions as an outlet for an unobstructed cooling channel 312, and allows cooling from a cooling chamber located within the part 300 (e.g., similar to...). Figure 2 Cooling air enters the cooling chamber 102a through a circular inlet (or first end) 314. The circular inlet 314 has a diameter D, and the shape of the channel 312 transitions at the opening 310 into a rectangular outlet having a width W and a length L. The opening area of ​​the inlet 314 may be approximately the same as the area of ​​the outlet 310 (e.g., ...). Figure 3 (as shown), or the area of ​​the discharge outlet 310 may be larger than that of the inlet 314 (as shown). Figure 4 (As shown in the illustration). For example only, the width W is approximately half the diameter D, and the length L is approximately 1.5 times the diameter D. Alternatively, the width W of the discharge port 310 may be equal to or less than half the diameter D of the inlet 314, and the length L of the discharge port 310 may be equal to or greater than 1.5 times the diameter D of the inlet 314, as shown in the illustration. Figure 4 As shown in the image.

[0066] Figure 5 A first step in a method of forming a cooling assembly according to an aspect of this disclosure is illustrated. An encapsulated diffuser insert 500 is partially placed in an aperture 302 located in a turbine component 300. The encapsulated diffuser insert 500 includes a central channel 312 through which cooling air will flow. At the inlet (or first end) 314 of the encapsulated diffuser insert 500, the opening has a generally circular (or slightly oval) cross-section. The opposite outlet / exhaust port 310 (or second end) has an elongated rectangular cross-sectional shape. The outlet 310 has a sacrificial cap 502 attached thereto, and the cap 502 prevents coating material from entering the channel 312.

[0067] Figure 6 An example is illustrated of the coating application steps for a coating applied to the outer surface of a turbine component. The coating 610 at least partially encapsulates the exposed portion of the encapsulated diffuser insert 500. The sacrificial cap 502 preferably remains at least partially exposed to facilitate subsequent identification and removal. The coating 610 may be a protective or thermal barrier coating protecting the component 300. The encapsulated diffuser insert 500 is now encapsulated by the component 300 and the coating 610.

[0068] Figure 7The steps for removing the sacrificial cap 502 are illustrated. The sacrificial cap 502 can be removed by grinding, machining, or etching, and once the sacrificial cap 502 is removed, the central channel 312 is immediately completely unobstructed. Unobstructed is defined as the absence of any obstruction in the central channel that prevents airflow. For example, channel 312 is completely open to airflow. Air flows unobstructed from inlet 314 to outlet 310. In contrast, porous materials allow water or air to flow through, but the water / air flow is blocked by non-porous areas of the material. Therefore, porous materials cannot allow air / water flow to be unobstructed. As will be seen, the encapsulated diffuser insert 500 remains in the hole 302 and defines the shape of the central cooling channel 312, as well as the shapes of inlet 314 and outlet 310. Outlet 310 has an elongated rectangular shape, which is more efficient in distributing cooling air across the outer surface 301 of part 300. The resulting increased efficiency will allow for higher turbine ignition temperatures, which improves turbine output while reducing heat loss. The end result is a more efficient turbine that generates more power with less fuel and causes less wear and tear on turbine components.

[0069] The encapsulated diffuser insert 500 also allows for better selection of the exhaust orifice geometry and shape. The encapsulated diffuser insert 500 can be manufactured (e.g., by brazing, additive manufacturing, extrusion, or machining) with very sharp edges to reduce frictional losses in the airflow. Sharp exhaust edges can also reduce turbulence in the exhaust airflow. The geometry of the exhaust orifice can also be easily trimmed for greater mechanical benefits. As previously described, instead of a circular exhaust orifice, an elongated rectangular diffuser orifice can be used. This elongated rectangular exhaust orifice distributes cooling air over a wider surface area of ​​the outer / external surface 301, thereby improving cooling efficiency and potentially reducing the number of cooling orifices required. Fewer cooling orifices translate to less cooling air, and less cooling air allows the turbine to use more of that air for combustion (and improved mechanical efficiency) purposes.

[0070] Figure 8This is a flowchart of a method 800 for forming a cooling assembly in a turbine component. Placement step 810 involves partially placing an encapsulated diffuser insert 500 into a hole 302 in the turbine component 300. The encapsulated diffuser insert 500 has an unobstructed central channel 312 having a generally circular cross-section at a first (or inlet) end 314 and an elongated rectangular cross-section at a second (or outlet) end 310. The inlet end 314 is opposite to the outlet end 310. The second (or outlet) end 310 has a sacrificial cap 502 that protects the central channel 312 from the subsequent coating step 820. Coating step 820 involves coating the turbine component 300 to at least partially encapsulate the encapsulated diffuser insert 500 in a coating 610. The coating may be a thermal barrier coating. Removal step 830 involves removing the sacrificial cap 502 to allow airflow through the central channel 312. The encapsulated diffuser insert 500 remains in the bore 302 and coating 610 of the turbine component, thereby providing an unobstructed central channel 312 having a generally circular first / inlet end 314 and an elongated rectangular second / exhaust end 310 adjacent to the outer surface 301 of the turbine component 300.

[0071] Figure 9 An enlarged cross-sectional view of a portion of the encapsulated diffuser insert 500 is illustrated, wherein the sacrificial cap 502 has a cap conduit 504 formed in a path having one or more inflection points. The cap conduit 504 provides a passage through which compressed air can be blown to remove powder from the channel 312. In additive manufacturing, and more specifically in powder bed fusion type machinery, powder can accumulate in the channel 312 during the fabrication of the insert 500. The bottom 314 of the insert 500 will be open, but it may take time to move all the powder out of the channel 312 via the bottom opening 314. The cap conduit 504 allows compressed air to be introduced from the top region of the sacrificial cap, and this air blows unused powder from the channel 312 out of the bottom opening 314. The curved or meandering path of the conduit 504 limits or prevents the coating layer 610 from obstructing the channel 312, because the conduit 504 will be blocked by the coating 610 before any (or any considerable amount) of the coating 610 can enter the channel 312. For example, the uppermost portion of the conduit 504 may be blocked by the coating layer 610, thereby protecting the central channel 312 from any obstructing coating material. Figure 10An enlarged cross-sectional view of a portion of the encapsulated diffuser insert 500 is illustrated, wherein the sacrificial cap 502 has a cap conduit 506 formed in a curved path. The conduit 506 will function similarly to the conduit 504, whereby it allows compressed air to enter during part manufacturing and is quickly blocked by the coating material 610, or essentially prevents the coating material 610 from reaching the channel 312 and causing obstruction. The cap conduit may also have multiple (e.g., two or more) bends or be meandering or spiral in shape.

[0072] Figure 11 A cross-sectional view of an encapsulated diffuser insert 500 shown is illustrated, indicating it is mechanically locked into a hole 302 in part 300. The bottom 314 of the encapsulated diffuser insert 500 may be cylindrical in shape, and this cylindrical portion may deform to wrap around or mechanically lock to part 300. For example, a segment 508 of the encapsulated diffuser insert 500 may be bent (or otherwise deformed) around the bottom of the hole 302 so that the encapsulated diffuser insert 500 is mechanically locked to part 300. As shown, the angled bend at the upper portion of the encapsulated diffuser insert 500 prevents the encapsulated diffuser insert 500 from further downward into the hole 302, and the bottom segment 508 prevents the encapsulated diffuser insert 500 from being pulled upward and out of the hole 302. The bottom portion of the encapsulated diffuser insert 500 may be cut to form a slit or groove therein, and the material remaining on each side of the slit / groove may be bent against the inner surface of the part 300, as shown. Alternatively, mechanical locking may be achieved by supporting the encapsulated diffuser insert 500 against the inner wall surface of the part 300 (if proximity is possible).

[0073] As used herein, elements or steps described in the singular and prefixed with "a" or "an" should be understood to not exclude a plurality of the stated elements or steps, unless such exclusion is expressly stated. Furthermore, references to "an embodiment" of the subject matter currently described are not intended to be construed as excluding the existence of additional embodiments that also include the described features. Moreover, unless expressly stated to the contrary, embodiments that "comprise" or "contain" one or more elements having a particular characteristic may include additional such elements that do not have that characteristic.

[0074] It should be understood that the above description is intended to be illustrative and not restrictive. For example, the above embodiments (and / or aspects thereof) may be used in combination with each other. Furthermore, many modifications may be made to adapt a particular situation or material to the teachings of the subject matter set forth herein without departing from its scope. While the dimensions and types of materials described herein are intended to define parameters of the disclosed subject matter, they are by no means limiting and are exemplary embodiments. Many other embodiments will be apparent to those skilled in the art after reading the above description. The scope of the subject matter described herein should therefore be determined with reference to the appended claims, together with the full scope of the equivalents granted by these claims. In the appended claims, the terms “comprising” and “therein” are used as colloquial equivalents of the corresponding terms “including” and “wherein”. Moreover, in the following claims, the terms “first,” “second,” and “third,” etc., are used merely as labels and are not intended to impose numerical requirements on their objects. Furthermore, the limitations of the following claims are not written in the device plus function format and are not intended to be interpreted based on 35 USC §112(f), unless or until such a claim limitation expressly uses the phrase “for a device” followed by a functional statement without any other structure.

[0075] This written description uses examples to disclose several embodiments of the subject matter set forth herein, including best practices, and also enables those skilled in the art to practice embodiments of the disclosed subject matter, including making and using any device or system and performing methods. The patentability of the subject matter described herein is defined by the claims and may include other examples that would occur to those skilled in the art. Such other examples are intended to be within the scope of the claims if they include structural elements that are not different from the literal language of the claims, or if they include equivalent structural elements that are not significantly different from the literal language of the claims.

Claims

1. A method for forming a cooling assembly in a turbine component, the method comprising: The encapsulated diffuser insert is partially placed into a hole in the turbine component, the encapsulated diffuser insert having an unobstructed central channel having a generally circular cross-section at a first end and an elongated rectangular cross-section at a second end opposite to the first end, the second end having a sacrificial cap; The turbine parts are coated to at least partially encapsulate the packaged diffuser insert within the coating. The sacrificial cap is removed to allow airflow through the central channel, wherein the encapsulated diffuser insert remains in the hole and the coating of the turbine component, thereby providing the unobstructed central channel having a generally circular first end and an elongated rectangular second end adjacent to the outer surface of the turbine component.

2. The method according to claim 1, wherein the first end has a first diameter of the generally circular cross-section, and the second end has a second width and a second length of the elongated rectangular cross-section; and in, The second width is approximately half the first diameter, and the second length is approximately one and a half times the first diameter.

3. The method according to claim 1, wherein the first end has a first diameter of the generally circular cross-section, and the second end has a second width and a second length of the elongated rectangular cross-section; and in, The second width is equal to or less than half the first diameter, and the second length is equal to or greater than 1.5 times the first diameter.

4. The method according to claim 1, wherein, The area of ​​the first end is approximately equal to the area of ​​the second end.

5. The method according to claim 1, wherein, The area of ​​the first end is not equal to the area of ​​the second end.

6. The method according to claim 1, further comprising: Prior to the placement step, the diffuser insert of the package is formed by at least one of the following: brazing, additive manufacturing, extrusion, and machining.

7. The method according to claim 1, wherein, The unobstructed central channel of the encapsulated diffuser insert is a completely unobstructed channel with a diffusion outlet.

8. The method according to claim 1, wherein the placement step further comprises: The packaged diffuser insert is secured in the hole by at least one of the following: welding, gluing, or mechanical locking.

9. The method according to claim 1, wherein the coating step further comprises: The turbine parts are coated with a thermal barrier coating.

10. The method according to claim 1, wherein, The turbine components are blades or nozzles.

11. The method of claim 1, wherein the sacrificial cap comprises a cap conduit formed in a curved path or a path having one or more inflection points.

12. The method according to claim 1, wherein the placement step further comprises: The encapsulated diffuser insert is fixed in the hole by friction engagement.

13. The method according to claim 1, wherein, The turbine component is a guide vane.

14. A method of forming a cooling assembly in a turbine component, the method comprising: The encapsulated diffuser insert is partially placed into a hole in the turbine component, the encapsulated diffuser insert having an unobstructed central channel having a generally circular cross-section at a first end and an elongated rectangular cross-section at a second end opposite to the first end, the second end having a sacrificial cap; The turbine parts are coated with a thermal barrier coating to at least partially encapsulate the encapsulated diffuser insert within the thermal barrier coating; The sacrificial cap is removed to allow airflow through the central channel, the encapsulated diffuser insert remaining in the orifice and thermal barrier coating of the turbine component, thereby providing the unobstructed central channel having a generally circular first end and an elongated rectangular second end adjacent to the outer surface of the turbine component, wherein the turbine component is a blade or a nozzle.

15. The method of claim 14, wherein the first end has a first diameter of the generally circular cross-section, and the second end has a second width and a second length of the elongated rectangular cross-section; The second width is approximately half the first diameter, and the second length is approximately 1.5 times the first diameter; or The second width is equal to or less than half the first diameter, and the second length is equal to or greater than 1.5 times the first diameter.

16. The method according to claim 15, wherein, The area of ​​the first end is approximately equal to the area of ​​the second end, or the area of ​​the first end is not equal to the area of ​​the second end.

17. The method of claim 14, further comprising: Prior to the placement step, the diffuser insert of the package is formed by at least one of the following: brazing, additive manufacturing, extrusion, and machining.

18. The method of claim 14, wherein the placement step further comprises: The packaged diffuser insert is secured in the hole by at least one of the following: welding, gluing, or mechanical locking.

19. The method of claim 14, wherein the sacrificial cap comprises a cap conduit formed in a curved path or a path having one or more inflection points.

20. The method of claim 14, wherein, The turbine component is a guide vane.

21. The method of claim 14, wherein the placement step further comprises: The encapsulated diffuser insert is fixed in the hole by friction engagement.

22. A method of forming a cooling assembly in a turbine component, the method comprising: The encapsulated diffuser insert is partially placed into a hole in the turbine component. The encapsulated diffuser insert has an unobstructed central channel with a generally circular cross-section at a first end and an elongated rectangular cross-section at a second end opposite to the first end. The second end has a sacrificial cap with a cap conduit formed in a curved path or a path with one or more inflection points. The packaged diffuser insert is secured in the hole by at least one of the following: welding, gluing, or mechanical locking; The turbine parts are coated with a protective coating to at least partially encapsulate the packaged diffuser insert within the protective coating; The sacrificial cap is removed to allow airflow through the central channel, and the encapsulated diffuser insert remains in the hole and the protective coating of the turbine component, thereby providing the unobstructed central channel having a generally circular first end and an elongated rectangular second end adjacent to the outer surface of the turbine component.

23. The method of claim 22, wherein the first end has a first diameter of the generally circular cross-section, and the second end has a second width and a second length of the elongated rectangular cross-section; The second width is approximately half the first diameter, and the second length is approximately 1.5 times the first diameter; or The second width is equal to or less than half the first diameter, and the second length is equal to or greater than 1.5 times the first diameter.

24. The method according to claim 23, wherein, The area of ​​the first end is approximately equal to the area of ​​the second end, or the area of ​​the first end is not equal to the area of ​​the second end.

25. The method according to claim 22, wherein, The method further includes: The encapsulated diffuser insert is fixed in the hole by friction engagement.

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