Coated parts with adaptive cooling openings and methods of making the same

Abstract

The present invention discloses a component comprising an outer wall having an outer surface and at least one storage tank defined within the outer wall and configured to receive cooling fluid therein. The component also includes a coating system disposed on the outer surface. The coating system has a thickness. The component further includes a plurality of adaptive cooling openings defined in the outer wall. Each adaptive cooling opening extends outwardly through the outer surface from a first end in flow communication with the at least one storage tank to a second end, the second end covering at least a portion of the thickness of the coating system.

Description

Background Technology

[0001] The field of this disclosure generally relates to components including internal cooling conduits, and more specifically to components including a series of cooling openings defined in an outer wall, initially closed by an outer wall coating system to facilitate adaptive cooling of the outer wall.

[0002] Some components (such as hot gas path components of a gas turbine) are subjected to high temperatures. At least some of these components have internal cooling channels defined therein, such as, but not limited to, networks of reservoirs and passageways, which allow cooling fluid to flow internally (e.g., along the inner surface of the component's outer wall). Additionally, at least some of these components include coating systems, such as thermal barrier coatings and adhesive layers, on the outer surface of the outer wall. The coating system and the cooling fluid each contribute to keeping one or more of the outer surface of the outer wall, other parts of the wall, or the component's base material, thermal barrier coating, and adhesive layer below their respective threshold temperatures during operation. In at least some cases, localized areas of the thermal adhesive layer may peel off or otherwise be damaged during the component's operational life, and an increased total flow rate of cooling fluid is chosen to compensate for the potential loss of protection of the thermal adhesive layer in the peeled areas. For at least some components, peeled areas may occur at any of a plurality of locations within the component, and therefore an increased total cooling fluid flow must be provided to the entire component, rather than just to the targeted areas. This can lead to unnecessary supercooling of areas where peeling has not occurred, thus reducing operational efficiency. Summary of the Invention

[0003] In one aspect, a component is provided. The component includes an outer wall having an outer surface and at least one storage tank defined within the outer wall and configured to receive cooling fluid therein. The component also includes a coating system disposed on the outer surface. The coating system has a thickness. The component further includes a plurality of adaptive cooling openings defined in the outer wall. Each adaptive cooling opening extends outwardly through the outer surface from a first end in flow communication with the at least one storage tank to a second end, the second end covering at least a portion of the thickness of the coating system.

[0004] In another aspect, a rotating machine is provided. The rotating machine includes a burner section configured to generate combustion gases; and a turbine section configured to receive the combustion gases from the burner section and thereby generate mechanical rotational energy. A path of combustion gases through the rotating machine defines a hot gas path. The rotating machine also includes a component near the hot gas path. This component includes an outer wall having an outer surface and at least one storage tank defined within the outer wall and configured to receive cooling fluid therein. The component also includes a coating system disposed on the outer surface. The coating system has a thickness. The component also includes a plurality of adaptive cooling openings defined in the outer wall. Each adaptive cooling opening extends outwardly through the outer surface from a first end in flow communication with the at least one storage tank to a second end, the second end being covered under at least a portion of the thickness of the coating system.

[0005] In another aspect, a method for manufacturing a component is provided. The method includes forming an outer wall that closes at least one storage tank. The at least one storage tank is configured to receive cooling fluid therein. The outer wall includes an outer surface and a plurality of adaptive cooling openings defined in the outer wall. The method further includes disposing a coating system on the outer surface. The coating system has a thickness. Each adaptive cooling opening extends outwardly through the outer surface from a first end in flow communication with the at least one storage tank to a second end, the second end being covered by at least a portion of the thickness of the coating system. Attached Figure Description

[0006] Figure 1 This is a schematic diagram of an exemplary rotating machine;

[0007] Figure 2 Is with Figure 1 A schematic perspective view of exemplary components used in conjunction with the rotating machine shown;

[0008] Figure 3 It is along Figure 2 The line shown in line 3-3 is cut off. Figure 2 A schematic cross-section of the component shown;

[0009] Figure 4 yes Figure 2 and Figure 3 A schematic perspective cross-sectional view of a portion of the component shown, in which the portion is... Figure 3 The middle section is designated as part 4;

[0010] Figure 5 yes Figure 4 A schematic perspective cross-sectional view of an exemplary outer wall of the component shown, the outer wall including an exemplary peeling area;

[0011] Figure 6 It is possible Figure 5A schematic perspective view of an exemplary adaptive cooling opening used in the outer wall, taken from another orientation;

[0012] Figure 7 yes Figure 2 and Figure 3 A schematic cross-sectional view of another exemplary outer wall of the component shown;

[0013] Figure 8 yes Figure 7 A schematic cross-sectional view of an exemplary outer wall, which includes another exemplary peeling area;

[0014] Figure 9 yes Figure 7 A schematic cross-sectional view of an exemplary manufacturing stage of an exemplary outer wall;

[0015] Figure 10 yes Figure 2 and Figure 3 A schematic cross-sectional view of another exemplary outer wall of the component shown; and

[0016] Figure 11 yes Figure 2 A schematic cross-sectional view of another exemplary outer wall of the component shown, which includes another exemplary embodiment of an adaptive cooling opening. Detailed Implementation

[0017] In the following specification and claims, several terms will be referenced, and these terms shall be defined as having the following meanings.

[0018] Unless the context clearly indicates otherwise, the singular forms “a,” “an,” and “the” include plural references.

[0019] "Optional" or "optionally" means that the event or situation described below may or may not occur, and the description includes instances where the event occurs and instances where the event does not occur.

[0020] As used throughout the specification and claims, approximate language can be used to modify any quantitative expression that may be varied without causing a change in its underlying function. Therefore, values ​​modified by one or more terms (such as “about,” “approximately,” and “substantially”) are not limited to specified precise values. In at least some cases, approximate language may correspond to the precision of the instrument used to measure the value. Scope limitations can be identified herein and throughout the specification and claims. Unless otherwise indicated by context or language, these scopes may be combined and / or interchanged, and include all subscopes contained herein.

[0021] Unless otherwise indicated, the terms “first,” “second,” etc., are used herein as illustrative purposes only and are not intended to impose any order, position, or hierarchical requirements on the items referred to by these terms. Furthermore, references to items such as “second” do not require or exclude the existence of items such as “first” or lower numbered and / or such as “third” or higher numbered.

[0022] The exemplary component described herein overcomes at least some of the drawbacks associated with known systems that achieve internal cooling of the component. More specifically, the embodiment described herein includes a plurality of adaptive cooling openings defined in the outer wall of the component. A coating is disposed on the outer surface of the outer wall. Each opening extends outward from a first end in flow communication with at least one internal reservoir of the component through the outer surface to a second end, the second end being covered beneath at least a portion of the coating thickness. After, for example, a peeling event damages or removes the coating to the depth of the second end of the adaptive cooling opening, cooling fluid from the internal cooling fluid path is directed through the adaptive cooling opening to the outside of the component, thereby providing additional localized cooling to mitigate, for example, the peeling event.

[0023] Figure 1 This is a schematic diagram of an exemplary rotating machine 10 having components that can be used with embodiments of the present disclosure. In an exemplary embodiment, the rotating machine 10 is a gas turbine including an intake section 12, a compressor section 14 coupled downstream of the intake section 12, a combustor section 16 coupled downstream of the compressor section 14, a turbine section 18 coupled downstream of the combustor section 16, and an exhaust section 20 coupled downstream of the turbine section 18. A generally tubular housing 36 at least partially encloses one or more of the intake section 12, compressor section 14, combustor section 16, turbine section 18, and exhaust section 20. In an alternative embodiment, the rotating machine 10 is any rotating machine to which components with internal passages formed as described herein are applicable. Furthermore, although embodiments of the present disclosure are described in the context of rotating machines for illustrative purposes, it should be understood that the embodiments described herein are applicable to any context involving components exposed to high-temperature environments.

[0024] In an exemplary embodiment, the turbine section 18 is coupled to the compressor section 14 via the rotor shaft 22. It should be noted that, as used herein, the term "coupled" is not limited to direct mechanical, electrical, and / or communication connections between components, but may also include indirect mechanical, electrical, and / or communication connections between multiple components.

[0025] During operation of the rotating machine 10, the intake section 12 directs air toward the compressor section 14. The compressor section 14 compresses the air to a higher pressure and temperature. More specifically, the rotor shaft 22 applies rotational energy to at least one circumferential row of compressor blades 40 coupled to the rotor shaft 22 within the compressor section 14. In an exemplary embodiment, each row of compressor blades 40 is preceded by a circumferential row of compressor stator blades 42 extending radially inward from the housing 36, which directs airflow into the compressor blades 40. The rotational energy of the compressor blades 40 increases the pressure and temperature of the air. The compressor section 14 discharges compressed air toward the burner section 16.

[0026] In the burner section 16, compressed air is mixed with fuel and ignited to generate combustion gases, which are directed toward the turbine section 18. More specifically, the burner section 16 includes at least one burner 24 in which fuel (e.g., natural gas and / or fuel oil) is injected into the air stream, and the fuel-air mixture is ignited to generate high-temperature combustion gases, which are directed toward the turbine section 18.

[0027] The turbine section 18 converts the thermal energy from the combustion gas flow into mechanical rotational energy. More specifically, the combustion gas applies rotational energy to at least one circumferential row of rotor blades 70 coupled to the rotor shaft 22 within the turbine section 18. In an exemplary embodiment, each row of rotor blades 70 is preceded by a circumferential row of turbine stator blades 72 extending radially inward from the housing 36, which guides the combustion gas into the rotor blades 70. The rotor shaft 22 may be coupled to a load (not shown), such as, but not limited to, generators and / or mechanical drive applications. The exhausted combustion gas flows downstream of the turbine section 18 into the exhaust section 20. The path of the combustion gas through the rotating machine 10 defines a hot gas path for the rotating machine 10. Components of the rotating machine 10 are designated as components 80. Components 80 near the hot gas path are subjected to high temperatures during operation of the rotating machine 10. In an alternative embodiment, component 80 is any component in any application exposed to a high-temperature environment.

[0028] Figure 2 This is a schematic perspective view of an exemplary component 80, shown as being associated with a rotating machine 10. Figure 1 (As shown) Use together. Figure 3 It is along line 3-3 ( Figure 2 (Shown) A schematic cross-section of component 80. Figure 4 This is a schematic perspective sectional view of a part of component 80, which is in Figure 3 Part 4 is designated as the middle section. (See reference...) Figures 2 to 4Component 80 includes an outer wall 94 having a pre-selected thickness 104. Furthermore, in an exemplary embodiment, component 80 includes at least one internal cavity 100 defined therein. For example, during operation of the rotating machine 10, cooling fluid 101 is supplied to the internal cavity 100 to help keep component 80 below the temperature of the hot combustion gases.

[0029] Component 80 is formed of component material 78. In an exemplary embodiment, component material 78 is a suitable nickel-based superalloy. In an alternative embodiment, component material 78 is at least one of a cobalt-based superalloy, an iron-based alloy, and a titanium-based alloy. In other alternative embodiments, component material 78 is a ceramic matrix composite (CMC). In yet another alternative embodiment, component material 78 is any suitable material that enables component 80 to function as described herein.

[0030] In an exemplary embodiment, component 80 is either rotor blade 70 or stator blade 72. In another embodiment, component 80 is another suitable component of rotating machine 10. In yet another embodiment, component 80 is any component in any application exposed to high-temperature environments.

[0031] In an exemplary embodiment, the rotor blade 70 or alternatively the stator blade 72 includes a pressure side 74 and an opposing suction side 76. Each of the pressure side 74 and the suction side 76 extends from a leading edge 84 to an opposing trailing edge 86. Additionally, the rotor blade 70 or alternatively the stator blade 72 extends from a root end 88 to an opposing tip 90. A longitudinal axis 89 of the component 80 is defined between the root end 88 and the tip 90. In an alternative embodiment, the rotor blade 70 or alternatively the stator blade 72 has any suitable configuration capable of being formed with a pre-selected outer wall thickness as described herein.

[0032] The outer wall 94 at least partially defines the outer surface 92 of the component 80 and the inner surface 93 opposite to the outer surface 92. In an exemplary embodiment, the outer wall 94 extends circumferentially between a leading edge 84 and a trailing edge 86, and also extends longitudinally between a root end 88 and a tip 90. In an alternative embodiment, the outer wall 94 extends to any suitable extent that enables the component 80 to function for its intended purpose. The outer wall 94 is formed of component material 78.

[0033] Additionally, at least one internal cavity 100 includes at least one storage groove 110 defined within the outer wall 94. In an exemplary embodiment, each storage groove 110 extends from the root end 88 to the vicinity of the tip 90. In an alternative embodiment, each storage groove 110 extends within the component 80 in any suitable manner to any suitable extent that enables the component 80 to function as described herein.

[0034] For example, in Figure 4 In the illustrated embodiment, component 80 includes an inner wall 96 positioned within an outer wall 94, and at least one storage compartment 110 is at least partially defined by the inner wall 96 and its interior. In an exemplary embodiment, at least one storage compartment 110 includes a plurality of storage compartments 110, each defined by an inner wall 96 and at least one partition wall 95 extending at least partially between the pressure side 74 and the suction side 76. For example, in the illustrated embodiment, each partition wall 95 extends from the outer wall 94 of the pressure side 74 to the outer wall 94 of the suction side 76. In an alternative embodiment, at least one partition wall 95 extends from the inner wall 96 of the pressure side 74 to the inner wall 96 of the suction side 76. Additionally or alternatively, at least one partition wall 95 extends from the inner wall 96 of the pressure side 74 to the outer wall 94, and / or from the inner wall 96 of the suction side 76 to the outer wall 94. In other alternative embodiments, at least one internal cavity 100 includes any suitable number of storage compartments 110 defined in any suitable manner. The inner wall 96 is formed of component material 78.

[0035] Furthermore, in some embodiments, at least a portion of the inner wall 96 extends circumferentially and longitudinally near and spaced apart from at least a portion of the outer wall 94 by an offset distance 98, such that at least one internal void 100 also includes at least one chamber 112 defined between the inner wall 96 and the outer wall 94. In an exemplary embodiment, the at least one chamber 112 includes a plurality of chambers 112, each defined by the outer wall 94, the inner wall 96, and at least one partition wall 95. In another embodiment, the at least one chamber 112 includes any suitable number of chambers 112 defined in any suitable manner. In an exemplary embodiment, the inner wall 96 has a thickness 107 and defines a plurality of holes 102 extending therethrough, such that each chamber 112 is in flow communication with at least one storage tank 110.

[0036] In an exemplary embodiment, the offset distance 98 is selected to facilitate effective impact cooling of the outer wall 94 by the cooling fluid 101, which is supplied through the storage tank 110 and discharged through the orifice 102 defined in the inner wall 96 toward the inner surface 93 of the outer wall 94. For example, but not as a limitation, the offset distance 98 varies circumferentially and / or longitudinally along the component 80 to facilitate localized cooling requirements along a corresponding portion of the outer wall 94. In an alternative embodiment, the offset distance 98 is selected in any suitable manner. Additionally, in an exemplary embodiment, the orifice 102 is arranged in a pattern 103, which is selected to facilitate effective impact cooling of the outer wall 94. For example, but not as a limitation, the pattern 103 varies circumferentially and / or longitudinally along the component 80 to facilitate localized cooling requirements along a corresponding portion of the outer wall 94. In an alternative embodiment, the pattern 103 is selected in any suitable manner.

[0037] In some embodiments, the respective size and shape of the orifices 102 are configured to allow cooling fluid 101 to pass through them in the form of an impinging jet 105 and discharge toward the inner surface 93. For example, each orifice 102 has a substantially circular or oval cross-section. In alternative embodiments, each orifice 102 has any suitable shape and size that enables the orifice 102 to function as described herein.

[0038] In an exemplary embodiment, the outer wall 94 substantially bears the operational load of the component 80, while the inner wall 96 and / or partition wall 95 are formed by at least one insert baffle that bears a very small load. In an alternative embodiment, the inner wall 96 and / or partition wall 95 are integrally formed with the outer wall 94 and / or bear a large portion of the operational load of the component 80.

[0039] In another exemplary embodiment, the outer wall 94 defines the boundary between the component 80 and the hot gas environment and has a thickness 104, which is chosen to facilitate effective cooling of the outer wall 94 while reducing the flow of cooling fluid 101, compared to components with thicker outer walls. In another embodiment, the outer wall thickness 104 is any suitable thickness that enables the component 80 to function for its intended purpose. In some embodiments, the outer wall thickness 104 varies along the outer wall 94. In another embodiment, the outer wall thickness 104 is constant along the outer wall 94.

[0040] In an exemplary embodiment, the outer wall 94 includes discharge openings 99 extending therethrough, which, upon startup of component 80, are not blocked by the coating system 200 (described below) and allow cooling fluid 101 to drain through it from chamber 112, thus providing baseline film cooling of the exterior of the outer wall 94 in addition to the adaptive cooling described below. In an alternative embodiment, the outer wall 94 does not include discharge openings 99, and at least one internal void 100 includes at least one return channel 114 in flow communication with at least one chamber 112, such that each return channel 114 provides a return fluid flow path for the cooling fluid 101 used for impingement cooling of the outer wall 94. In other alternative embodiments, component 80 includes both discharge openings 99 and return channels 114. Although at least one internal cavity 100 is shown as including a storage tank 110, a chamber 112, and an optional return channel 114 for cooling component 80 (which is either rotor blade 70 or stator blade 72), it should be understood that in alternative embodiments, component 80 is any suitable component for any suitable application and includes any suitable number, type, and arrangement of internal cavities 100 that enable component 80 to function for its intended purpose. For example, in some embodiments, component 80 is not configured for shock cooling of the outer wall 94.

[0041] In an exemplary embodiment, component 80 further includes a coating system 200 disposed on the outer surface 92 of the outer wall 94. The coating system 200 is formed of at least one material selected to protect the outer wall 94 from high-temperature environments. For example, as relative to… Figure 7 In more detail, coating system 200 includes a suitable adhesive layer adjacent to and configured to adhere to outer surface 92, and one or more suitable thermal barrier outer layers adjacent to the adhesive layer. In an alternative embodiment, coating system 200 is formed of any suitable material or combination of materials applied in any suitable layer and thickness combination. Coating system 200 has a total thickness 204. For clarity of illustration, Figure 2 The coating system 200 is hidden inside.

[0042] For example, during operation, cooling fluid 101 is supplied through the root end 88 of component 80 to the storage tank 110. As the cooling fluid flows generally toward the tip 90, a jet 105 of cooling fluid 101 is forced through the orifice 102 into the chamber 112 and impacts the inner surface 93 of the outer wall 94. In an exemplary embodiment, the used cooling fluid 101 then flows through a discharge opening 99 extending through the outer wall 94 and the coating system 200. For example, the cooling fluid 101 is discharged into the working fluid through a predefined unobstructed discharge opening 99, thereby facilitating baseline film cooling of the outer surface 92 and the coating system 200 in addition to the adaptive cooling described below.

[0043] In an alternative embodiment, the used cooling fluid 101 is directed into a return channel 114 and flows out of the component 80 generally toward the root end 88. In some such embodiments, the arrangement of at least one storage tank 110, at least one chamber 112, and at least one return channel 114 forms part of the cooling circuit of the rotating machine 10, such that the used cooling fluid 101 flows from the burner section 16 ( Figure 1 (As shown) The upstream fluid flows through the rotating machine 10 back to the working fluid flow. In other alternative embodiments, component 80 includes both a return channel 114 and a discharge opening 99, through which the first portion of the cooling fluid 101 flows from the burner section 16 (shown). Figure 1(As shown) The upstream flow returns to the working fluid flow through the rotating machine 10, and a second portion of the cooling fluid 101 is discharged into the working fluid through the discharge opening 99 to facilitate baseline film cooling of the outer surface 92 and the coating system 200. Although the impinging flow through the storage tank 110 and chamber 112 and the discharge flow optionally through the discharge opening 99 or the return flow through the channel 114 are described in an embodiment where component 80 is rotor blade 70 and / or stator blade 72, the loop of storage tank 110, chamber 112, discharge opening 99 and / or return channel 114 is applicable to any component 80 of the rotating machine 10, and also to any suitable component 80 for any other application.

[0044] The outer wall 94 includes a plurality of adaptive cooling openings 120 defined therein and extending therethrough. More specifically, each adaptive cooling opening 120 extends outwardly through the outer surface 92 from a first end 122 in flow communication with at least one storage tank 110 to a second end 124. In an exemplary embodiment, the first end 122 is defined in and extends through an inner surface 93 of the outer wall 94 and is in flow communication with at least one storage tank 110 via at least one chamber 112. In an alternative embodiment, the first end 122 is defined at any suitable location within the outer wall 94 in flow communication with at least one storage tank 110. For example, the first end 122 is in flow communication with a channel 170 that extends generally parallel to the outer surface 92 within the outer wall 94, as described herein with respect to Figure 11 describe.

[0045] In some implementation schemes, and as such Figure 4 As shown, the second end 124 is defined at the outer surface 92 of the outer wall 94 and extends through the outer surface, such that the second end 124 lies beneath the entire thickness 204 of the coating system 200. In other embodiments, the second end 124 is defined within the coating system 200 such that the adaptive cooling opening 120 partially extends into the coating system 200, as will be referred to herein with respect to... Figure 7Description. In any case, in an exemplary embodiment, after component 80 begins operation, the second end 124 of each adaptive cooling opening 120 covers at least a portion of the thickness 204 of the coating system 200, such that the coating system 200 at least partially blocks the cooling fluid 101 from discharging through the outer wall 94 via the adaptive cooling opening 120. In other words, after component 80 begins operation, the adaptive cooling opening 120 is at least partially blocked by the coating system 200. In some such embodiments, the coating system 200 is porous, such that during operation, even when the coating system 200 is intact above the adaptive cooling opening 120, a portion of the cooling fluid 101 escapes through the adaptive cooling opening 120, thereby further facilitating cooling of the outer surface 92 of the outer wall 94 and the baseline film of the coating system 200. In other such embodiments, the coating system 200 is non-porous, such that when the coating system 200 is intact above the adaptive cooling opening 120, the coating system 200 effectively blocks the adaptive cooling opening 120.

[0046] Figure 4 An exemplary peeling area 250 is also shown, from which at least a portion of the coating system 200 has been removed when the component 80 is in operation. Figure 5 This is a perspective view of the outer wall 94 of the component 80, including the exemplary peeling area 250. For example, when the coating system 200 is in a rotating machine 10 ( Figure 1 Region 250 is formed when the component 80 peels off during operation or is otherwise degraded by the high-temperature environment (as shown). In some embodiments, component 80 is a rotating machine 10 (shown). Figure 1 The component 80 is one of the rotor blades 70 or stator blades 72 (as shown), and a spalling region 250 is formed along the leading edge 84 of the component 80. In an alternative embodiment, the component 80 is any component in any application exposed to a high-temperature environment, and / or the spalling region 250 is formed at any location on the component 80.

[0047] exist Figure 4 and Figure 5 In the illustrated embodiment, the entire thickness 204 of the coating system 200 has been removed from the peeling region 250, thereby exposing the outer surface 92 directly to the high-temperature operating environment. In an alternative embodiment, only a portion of the thickness 204 is removed or damaged in the peeling region 250. For example, the outer layer of the coating system 200 is delaminated in the peeling region 250, as will be referred to herein relative to... Figure 7 and Figure 8 To describe in more detail.

[0048] Damage to or removal of the coating system 200 increases the heat exposure of the outer wall 94 in the peeled area 250 and the exposed portion 252 of the coating system 200. Adaptive cooling openings 120 enable the component 80 to adapt to the increased cooling demands in the peeled area 250. More specifically, when the coating system 200 is removed, the second end 124 of each adaptive cooling opening 120 within the peeled area 250 becomes fully open, forming a flow channel for cooling fluid 101 to reach the exterior of the outer wall 94 from the at least one storage tank 110 through the adaptive cooling opening 120, thereby providing additional localized cooling (e.g., internal cavity cooling and / or external film cooling) to the outer wall 94 in the peeled area 250 and the exposed portion 252 of the coating system 200, in addition to the initial cooling provided by the internal cooling circuit within the component 80.

[0049] Because unobstructed flow through the adaptive cooling opening 120 occurs only within the spalling region 250, the resulting adaptive cooling response is self-adjusted in response to the size and location of the spalling region 250. In some embodiments, although the total flow rate of the cooling fluid 101 of component 80 must take into account the potential spalling region 250 to be formed, the total flow rate requirement of the cooling fluid 101 of component 80 is reduced compared to similar components designed to include permanent through openings over a larger area of ​​the outer wall 94, because the discharge of cooling flow is adaptively limited to the spalling region 250 formed by component 80 during operation. Furthermore, in some embodiments, the cooling provided by the adaptive cooling opening 120 contributes to the mitigation of spalling events, for example, by maintaining the integrity of the exposed portion 252 of the outer wall 94 and / or coating system 200 in region 250 and preventing the size of the spalling region 250 from increasing.

[0050] In some embodiments, the system with component 80 installed is such as the rotating machine 10 in the exemplary embodiment. Figure 1(As shown) includes additional subsystems configured to modify at least one characteristic of the cooling fluid 101 supplied to component 80 in response to the occurrence of the spalling zone 250. For example, in some such embodiments, the system includes an auxiliary compressor 60 upstream of component 80. The auxiliary compressor 60 increases the pressure of the cooling fluid 101 supplied to at least one storage tank 110 and thus increases the flow rate of the cooling fluid to account for the additional flow rate required to supply the adaptive cooling openings 120 in the spalling zone 250. Additionally, in some such embodiments, the system includes a heat exchanger 62 located upstream of the auxiliary compressor 60 and configured to reduce the temperature of the cooling fluid 101. For example, the heat exchanger 62 reducing the temperature of the cooling fluid 101 facilitates subsequent compression of the cooling fluid 101 by the auxiliary compressor 60 and / or improves the cooling effect of the cooling fluid 101 supplied to component 80. Alternatively, the auxiliary compressor 60 may be used without the heat exchanger 62.

[0051] In some embodiments, the operation of the auxiliary compressor 60 and heat exchanger 62 (if present) is selectively adjusted based on the operating time of the plurality of components 80 in the system. For example, the operating time may be used to assume a certain degree of spalling or other damage to component 80, and the auxiliary compressor 60 and heat exchanger 62 may be adjusted in response to the assumed degree of damage to increase the flow rate of cooling fluid 101 and / or the cooling effect. Alternatively, in some embodiments, the auxiliary compressor 60 and heat exchanger 62 may be actively controlled based on at least one suitable measured operating parameter of the system. For example, a detected change in the value of at least one measured operating parameter may indicate that a threshold volume of cooling fluid 101 flows through the spalling region 250 of the plurality of components, and in response, the auxiliary compressor 60 and heat exchanger 62 may be automatically controlled to increase the flow rate of cooling fluid 101 and / or the cooling effect. In another embodiment, the auxiliary compressor 60 and heat exchanger 62 are operated in any suitable manner to enable the auxiliary compressor 60 and heat exchanger 62 to function as described herein. In other alternative embodiments, the system does not include the auxiliary compressor 60 and heat exchanger 62.

[0052] Despite the adaptive cooling opening 120 in Figure 4 and Figure 5 The openings are shown extending from the first end 122 to the second end 124 in a direction generally perpendicular to the outer wall 94, but in some embodiments, the orientation of at least one adaptive cooling opening 120 is not perpendicular to the outer wall 94. More specifically, see reference to... Figure 6 In some embodiments, at least one adaptive cooling opening 120 is oriented at an acute angle relative to a direction 97 perpendicular to the outer wall 94. Figure 6One such embodiment is illustrated in the figure, which is a schematic perspective view of an exemplary arrangement 150 of adaptive cooling openings 120 that can be used in the outer wall 94. Figure 6 In the illustration, for ease of explanation, a portion of the outer wall 94 surrounding the arrangement 150 of the adaptive cooling opening 120 is shown as transparent by dashed lines.

[0053] In an exemplary embodiment, each adaptive cooling opening 120 is oriented at the same acute angle 142 measured relative to the normal direction 97, but the direction of rotation may differ, as discussed further below. In an alternative embodiment, the size of the acute angle 142 of at least one adaptive cooling opening 120 differs from the acute angle 142 of another adaptive cooling opening 120. In some embodiments, each acute angle 142 is selected to be in the range of about 30 degrees to about 60 degrees. More specifically, in an exemplary embodiment, each acute angle 142 is selected to be about 37 degrees. In an alternative embodiment, each acute angle 142 is selected to be any suitable size that allows the adaptive cooling opening 120 to function as described herein. In some embodiments, an adaptive cooling opening 120 oriented at an acute angle 142 is advantageous for enhancing cooling along the spalling region 250 ( Figure 5 The exposed portion 252 (shown) cools the coating system 200. More specifically, in some such embodiments, an adaptive cooling opening 120 oriented at an acute angle 142 directs cooling fluid 101 at least partially toward the exposed portion 252, rather than in a normal direction 97 generally parallel to the edge of the exposed portion 252. For example, the cooling fluid 101 directed at least partially toward the exposed portion 252 enhances the cooling of the exposed portion 252, thereby suppressing overheating and further peeling of the coating system 200.

[0054] In an exemplary embodiment, arrangement 150 is formed by repeatedly distributing a group of adaptive cooling openings 120 (a group is shown) across outer wall 94, with each adaptive cooling opening 120 in the group rotated at an acute angle 142 in a direction different from the other adaptive cooling openings 120 in the group. Therefore, regardless of where the spalled area 250 is formed on outer surface 92, at least one of the adaptive cooling openings 120 will be oriented at least partially toward the exposed portion 252 of coating system 200, thereby facilitating enhanced cooling of the exposed portion 252 and thus inhibiting the enlargement of the spalled area 250.

[0055] For example, in the illustrated embodiment, each repeating group of arrangement 150 includes four adaptive cooling openings 120 arranged on four corresponding sides of the cubic portion of the outer wall 94. Each adaptive cooling opening 120 in the group is rotated at an acute angle 142 in different directions, and this direction of rotation advances 90 degrees relative to the adjacent adaptive cooling opening 120 in the group. Thus, a first end 122 of each adaptive cooling opening 120 is positioned directly below the second end 124 of the adjacent adaptive cooling opening 120. The illustrated arrangement 150 also facilitates oriented at least one of the adaptive cooling openings 120 at least partially toward the exposed portion 252 of the coating system 200, regardless of where the peeling area 250 is formed on the outer surface 92. In an alternative embodiment, each group of arrangement 150 includes any suitable number and orientation of adaptive cooling openings 120 that enable arrangement 150 to function as described herein.

[0056] In an alternative embodiment, at least some of the adaptive cooling openings 120 in each group are rotated at an acute angle 142 in the same direction. For example, in some embodiments, the outer wall 94 is exposed to external flow 160. Figure 5 The known, generally consistent direction of the working fluid flow (as shown) through the rotating machine 10 Figure 1 The adaptive cooling openings 120 are each oriented such that the second end 124 is at least partially tilted (i.e., at least partially facing) the direction of the oncoming external flow 160. Therefore, after the formation of the spalling region 250, each adaptive cooling opening 120 guides cooling fluid 101 from the second end 124 with a velocity component opposite to the external flow direction 160. Due to the change in local dynamic pressure of the external flow approaching the leading portion 253 and trailing portion 254 of the exposed portion 252 of the spalling region 250, the adaptive cooling openings 120 toward the central region of the spalling region 250 will flow with less cooling fluid 101, while the adaptive cooling openings 120 closest to the exposed portion 252 of the spalling region 250 will flow with more cooling fluid 101, thereby again suppressing overheating and further spalling of the coating system 200.

[0057] In an alternative embodiment, the adaptive cooling opening 120 is oriented in any suitable manner to enable the adaptive cooling opening 120 to function as described herein.

[0058] Figure 7 This is a schematic cross-sectional view of another exemplary embodiment of the outer wall 94 of component 80. Figure 8This is a schematic cross-sectional view of the outer wall 94, including another exemplary peeling region 250. In the illustrated embodiment, the coating system 200 includes an adhesive layer 210 adjacent to and configured to adhere to the outer surface 92, and at least one additional layer adjacent to the adhesive layer 210. More specifically, in an exemplary embodiment, the coating system 200 also includes an intermediate layer 212 adjacent to and configured to adhere to the adhesive layer 210, and an outer layer or insulating layer 214 adjacent to and configured to adhere to the intermediate layer 212. For example, in an exemplary embodiment, the adhesive layer 210 is an aluminum-rich material comprising diffused aluminate or McrAlY, where M is iron, cobalt, or nickel, and Y is yttrium or another rare earth element. In an alternative embodiment, the adhesive layer 210 is any suitable material that enables the adhesive layer 210 to function as described herein. In an exemplary embodiment, the intermediate layer 212 comprises yttrium-stabilized zirconium oxide. In an alternative embodiment, the intermediate layer 212 is any suitable material that enables the intermediate layer 212 to function as described herein. In an exemplary embodiment, the insulating layer 214 is an ultra-low thermal conductivity ceramic material comprising, for example, a zirconium or hafnium-based oxide lattice structure (ZrO2 or HfiO2) and an oxide stabilizer compound comprising one or more of the following (sometimes referred to as oxide "dopants"): ytterbium oxide (Yb2O3), yttrium oxide (Y2O3), hafnium oxide (HfO2), lanthanum oxide (La2O3), tantalum oxide (Ta2O5), and zirconium oxide (ZrO2). In an alternative embodiment, the insulating layer 214 is any suitable material that enables the insulating layer 214 to function as described herein. In an alternative embodiment, the coating system 200 comprises any suitable number and type of layers.

[0059] As discussed above, each of the adaptive cooling openings 120 extends outward from a first end 122, which is in flow communication with at least one storage tank 110, through an outer surface 92, to a second end 124. Figure 7 and Figure 8 In the illustrated embodiment, the second end 124 is defined in the coating system 200 such that the adaptive cooling opening 120 partially extends into the coating system 200. After the component 80 begins operation, the second end 124 of the adaptive cooling opening 120 covers a portion of the coating system 200 having a non-zero depth 220.

[0060] In an exemplary embodiment, the second end 124 is disposed within the outer layer or insulating layer 214 of the coating system 200 such that the adaptive cooling opening 120 extends through the entire thickness of the adhesive layer 210 and the intermediate layer 212, and through the thickness of only the first inner portion 216 of the insulating layer 214, thereby covering the second end 124 below the depth 220 of the remaining second outer portion 218 of the insulating layer 214. Therefore, when the peeling region 250 is formed to a depth at least equal to the depth 220 of the second portion 218 of the insulating layer 214 (e.g., ...), the peeling region 250 is formed. Figure 8 When (as shown), the second end 124 of each adaptive cooling opening 120 within the peeling region 250 becomes fully open, thereby forming a flow channel for cooling fluid 101 to reach the exterior of the outer wall 94 from at least one storage tank 110 through the adaptive cooling opening 120. This provides additional localized cooling (e.g., cavity cooling and / or external film cooling) to the outer wall 94 in the peeling region 250 and the exposed portion 252 of the coating system 200, in addition to the cooling provided by the internal cooling circuit within the component 80. In an alternative embodiment, the second end 124 is defined at any suitable depth 220 within the coating system 200 and / or terminates at or within any suitable layer of the coating system 200, thereby enabling the adaptive cooling opening 120 to function as described herein.

[0061] For example, in some embodiments, the peeling region 250 tends to originate as a delamination of the second portion 218 of the insulating layer 214 with the first portion 216 of the insulating layer 214, and a typical depth 220 of the second portion 218 can be empirically determined for each region of the outer wall 94. The design location of the second end 124 of the adaptive cooling opening 120 in each region of the outer wall 94 is then selected to correspond to the typical depth 220 of that region, such that the adaptive cooling opening 120 becomes active at the most common initial delamination depth in each region of the outer wall 94. Therefore, the depth of the second end 124 of the adaptive cooling opening 120 is selected to facilitate the mitigation of initial delamination peeling events, for example, in a way that maintains the integrity of the remaining layers of the outer wall 94 and / or coating system 200 in region 250 and prevents the size of the peeling region 250 from increasing. In alternative embodiments, the design location of the second end 124 is selected in any suitable manner to enable the adaptive cooling opening 120 to function as described herein.

[0062] In an alternative embodiment, the second end 124 is defined at the interface between the adhesive layer 210 and the intermediate layer 212, and the intermediate layer 212 and the first portion 216 of the insulating layer 216 are porous materials, such that the insulating layer 214 delaminates or peels to a depth 220 to allow cooling fluid 101 to flow through the second end 124, the porous intermediate layer 212, and the porous first portion 216 to the outside of the coating system 200, as described above. In other alternative embodiments, the arrangement of the second end 124 and the porosity of at least one layer of the coating system 200 are selected in any suitable manner to increase the flow rate through the adaptive cooling opening 120 in response to a peeling or delamination event at a corresponding depth. For example, the second end 124 is defined at the interface between the adhesive layer 210 and the intermediate layer 212, and the intermediate layer 212 is porous material, such that delamination or peeling of the entire thickness of the insulating layer 214 allows cooling fluid 101 to flow through the second end 124 and the porous intermediate layer 212 to the outside of the coating system 200, as described above.

[0063] Figure 9 Is it like this? Figure 7 A schematic cross-sectional view of an exemplary manufacturing stage of the outer wall 94 is shown. In an exemplary embodiment, a first portion of an adaptive cooling opening 120 extending from a first end 122 to an outer surface 92 is first formed in the outer wall 94 before the coating system 200 is added to the outer wall 94. For example, a component 80 having an outer wall 94 without the adaptive cooling opening 120 is first formed, and then the first portion of the adaptive cooling opening 120 is formed in the outer wall 94 by a suitable machining process. As another example, a component 80 having an outer wall 94 including a first portion of the adaptive cooling opening 120 defined therein is first formed. More specifically, the outer wall 94 is formed by casting molten metal component material 78 around a core shaped to define the first portion of the adaptive cooling opening 120 therein, or by an additive manufacturing process in which the adaptive cooling opening 120 is defined within a thin layer of component material 78, the thin layer of component material being continuously deposited to form the outer wall 94.

[0064] In some embodiments, before or during the application of the coating system 200 to the outer surface 92, a cap 230 is deployed at the second end 124 of each adaptive cooling opening 120 to define an adaptive cooling opening 120 below at least a portion of the coating system 200. In an exemplary embodiment, the cap 230 is a rectangular member inserted into a first portion of the adaptive cooling opening 120. More specifically, each cap 230 extends from a first end 232 to a second end 234, the first end being sized and shaped to be received in the first portion of the corresponding adaptive cooling opening 120, and the second end being sized and shaped to extend outward from the outer surface 92 to define a second end 124 of the corresponding adaptive cooling opening 120. After the cap 230 is positioned such that its second end 234 extends from the outer surface 92, the coating system 200 is applied to the outer surface 92 around and above the cap 230, such as by using a suitable spray deposition process in continuous layers. After the coating system 200 has reached the selected thickness 204, the second end 234 of each cover 230 defines the second end 124 of the corresponding adaptive cooling opening 120 at a depth 220 within the coating system 200, as follows: Figure 9 As shown.

[0065] In another embodiment, the cover 230 is a flat cover or overlay (not shown) positioned above the exposed outer end of each adaptive cooling opening 120 during each stage of deposition of the coating system 200, until defining an adaptive cooling opening 120 of the cover 230 extending to a second end 124. In other alternative embodiments, the cover 230 has any suitable structure that allows the adaptive cooling opening 120 to be formed as described herein.

[0066] In some embodiments, after the coating system 200 is formed, the cap 230 is removed from the outer wall 94 before the component 80 is started to operate. For example, the cap 230 is formed of a material that can be removed from the component 80 by a suitable leaching process before the component 80 is started to operate. Alternatively, the cap 230 is formed of a material configured to melt and be discharged from the component 80 by a suitable heating process before the component 80 is started to operate. In other embodiments, the cap 230 is not removed before the component 80 is started to operate, but is left in place until a peeling area 250 is formed above the cap 230. Figure 8 (As shown). For example, the cover 230 is formed of a material configured to burn off and / or fly away rapidly when the cover 230 is exposed to the high-temperature environment associated with the spalling area 250, thereby enabling the second end 124 of the corresponding adaptive cooling opening 120 to become unobstructed and form a flow channel so that the cooling fluid 101 can pass from the at least one storage tank 110 through the adaptive cooling opening 120 to the outside of the outer wall 94, as described above.

[0067] Figure 10 This is a schematic cross-sectional view of another exemplary embodiment including the outer wall 94 of the adaptive cooling opening 120. A cross-sectional region 126 of the adaptive cooling opening 120 is defined perpendicular to the normal direction 97. In some embodiments, the cross-sectional region 126 decreases substantially between a first end 122 and a second end 124. For example, in an exemplary embodiment, the adaptive cooling opening 120 defines a generally truncated conical shape within the outer wall 94, such that the cross-sectional region 126 is generally circular and decreases between the first end 122 and the second end 124. In alternative embodiments, each adaptive cooling opening 120 defines any suitable shape that enables the adaptive cooling opening 120 to function as described herein.

[0068] In some such embodiments, when a spalling region 250 is formed above the adaptive cooling opening 120 ( Figure 8 As shown, in some cases, deeper portions of the coating system 200 and the outer wall 94 are oxidized (i.e., “burned through”) or otherwise removed to a depth greater than the depth 220 of the second end 124. Because the cross-sectional area 126 increases substantially away from the second end 124 toward the first end 122, the increased depth of the peeling area 250 beyond the depth 220 tends to correspondingly increase the exposed cross-sectional area 126 of the adaptive cooling opening 120 in the peeling area 250, thereby increasing the escape of cooling fluid 101 through the adaptive cooling opening 120 and enhancing the adaptive film cooling effect. In some such embodiments, the shape of the adaptive cooling opening 120 is pre-selected to provide a varying cross-sectional area 126 that automatically “adjusts” the amount of film cooling provided in response to the severity of degradation of the coating system 200 and / or the outer wall 94 (e.g., width or depth). For example, as material burns off or flies away from the exposed portion 252 of the coating system 200, the cross-sectional area 126 opens up more and more until enough cooling flow is discharged from the adaptive cooling opening 120 to prevent any further degradation of the coating system 200.

[0069] Figure 11 This is a schematic cross-sectional view of another embodiment of the outer wall 94 of component 80, which includes another embodiment of adaptive cooling openings 120. Figure 11In one embodiment, component 80 does not include inner wall 96 and chamber 112, and outer wall 94 is not a relatively thin wall configured to receive shock cooling. Outer wall 94 includes at least one channel 170 defined therein, extending substantially parallel to outer surface 92 at a depth 172 from outer surface 92. For example, the at least one channel 170 is a plurality of suitable microchannels 170 configured to guide cooling fluid 101 through it near outer surface 92 to provide cooling to outer surface 92. In an exemplary embodiment, each channel 170 is in flow communication with at least one reservoir 110 via a corresponding inlet opening 174 defined within outer wall 94 between at least one reservoir 110 and a first end 171 of channel 170. In an alternative embodiment, each channel 170 is in flow communication with at least one reservoir 110 in any suitable manner to enable channel 170 to function as described herein.

[0070] In some embodiments, channel 170 includes a turbulence generator 180 along the surface defining channel 170. The turbulence generator 180 is configured to introduce and / or increase turbulence in the flow field of cooling fluid 101 within channel 170 to facilitate enhanced heat transfer. In an exemplary embodiment, the turbulence generator 180 is implemented as a series of bumps along the surface defining channel 170. In another embodiment, the turbulence generator 180 is implemented as indentations, ribs, other variations in the cross-sectional area of ​​channel 170, surface roughening areas, and any other structures that enable the turbulence generator 180 to function as described herein. In other alternative embodiments, channel 170 does not include the turbulence generator 180.

[0071] In an exemplary embodiment, each channel 170 extends to a second end (not shown) that extends through the outer surface 92 and the coating system 200, and the cooling fluid 101 is discharged into the working fluid through the second end of the channel 170. In an alternative embodiment, each channel 170 extends to a second end (not shown) that allows the cooling fluid 101 to return to another location in a closed cooling loop, such as a location within the rotating machine 10.

[0072] Each adaptive cooling opening 120 extends outward from a first end 122, which is in flow communication with at least one storage tank 110, through the outer surface 92 to a second end 124. In an exemplary embodiment, the first end 122 intersects and is in flow communication with a channel 170. In an alternative embodiment, the first end 122 is defined at any suitable location within an outer wall 94, which is in flow communication with at least one storage tank 110 via the channel 170 and / or the opening 174.

[0073] In some embodiments, as described above, the second end 124 is defined at the outer surface 92 of the outer wall 94 and extends through the outer surface. In other embodiments, the second end 124 is defined in the coating system 200 such that the adaptive cooling opening 120 extends partially into the coating system 200 and is positioned at a depth 220 within the coating system 200. Figure 11 Examples of these two embodiments are shown. In either case, after component 80 begins operation, the second end 124 of each adaptive cooling opening 120 covers at least a portion of the coating system 200, preventing cooling fluid 101 from draining through the outer wall 94 via the adaptive cooling opening 120. In other words, after component 80 begins operation, the adaptive cooling opening 120 is again blocked by the coating system 200. Therefore, when the peeling region 250 reaches a depth at least equal to the depth 220 of the second portion 218 of the insulating layer 214 (e.g., ... Figure 8 When (as shown), the second end 124 of each adaptive cooling opening 120 within the peeling region 250 becomes unobstructed, thereby forming a flow channel so that cooling fluid 101 can pass from at least one storage tank 110 through the adaptive cooling opening 120 to the outside of the outer wall 94, as described above.

[0074] Despite the adaptive cooling opening 120 in Figure 11 The first end 122 is shown extending from the second end 124 in a direction 97 generally perpendicular to the outer wall 94, but in some embodiments, the orientation of at least one adaptive cooling opening 120 is also not perpendicular to the outer wall 94. More specifically, in some embodiments, at least one adaptive cooling opening 120 is also oriented at an acute angle 142 relative to the direction 97, as described above relative to, for example... Figure 6 Description. Furthermore, in some such embodiments, groups of adaptive cooling openings 120 are oriented in arrangement 150 or another suitable arrangement (also as described above relative to, for example...). Figure 6 (Description) to facilitate the direction of cooling fluid 101 toward the exposed portion 252 of the spalling area 250, and / or to facilitate the direction of flow in the direction of external flow 160 ( Figure 5 (As shown) The opposite velocity component is guided from the second end 124 to the cooling fluid 101.

[0075] Compared to at least some known cooling systems, the above-described embodiments achieve improved mitigation of spalling or other degradation of the outer surface of internally cooled components. Specifically, the embodiments described herein include a component comprising a coating system disposed on its outer surface and a plurality of adaptive cooling openings defined in an outer wall. Each adaptive cooling opening extends outwardly through the outer surface from a first end in flow communication with at least one storage tank inside the component to a second end covering at least a portion of the thickness of the coating system, such that flow through the adaptive cooling opening is blocked by the coating system when the component begins operation. Once in operation, localized damage to the coating system, such as from a spalling event, exposes the second end of the adaptive cooling opening, and cooling fluid from the internal cooling fluid path is guided through the adaptive cooling opening to the outside of the component, thereby providing localized film or cavity cooling to mitigate, for example, the spalling event. Further specifically, in some embodiments, the adaptive cooling openings are oriented within the outer wall to facilitate the suppression of spalling area enlargement, for example, by ensuring that at least some of the adaptive cooling openings are angled toward the edge of the spalling area, regardless of where the spalling area may occur.

[0076] Exemplary technical effects of the methods, systems, and apparatuses described herein include at least one of the following: (a) mitigating the effects of spalling or other degradation of thermal barrier coatings on the outer surface and / or remaining coatings of internally cooled components; (b) selecting the depth of the end of an adaptive cooling opening below the initial thickness of the coating system based on empirical observations of the most common local depths of spalling and / or other coating system delamination events; and (c) automatically “adjusting” additional local cooling based on the size and depth of the spalled area.

[0077] The foregoing has described in detail exemplary embodiments of adaptive cooling components. The components, methods, and systems using such components are not limited to the specific embodiments described herein, but rather components and / or steps of the system and methods can be used independently and separately from other components and / or steps described herein. For example, exemplary embodiments can be implemented and utilized in conjunction with many other applications currently configured to use components in high-temperature environments.

[0078] Although specific features of the various embodiments of this disclosure may be shown in some figures and not in others, this is merely for convenience. Any feature of any of the figures may be referenced and / or claimed in accordance with the principles of this disclosure, in conjunction with any feature of any other figure.

[0079] This written description uses examples to disclose embodiments, including best practices, and also enables any person skilled in the art to practice these embodiments, including making and using any device or system and performing any combined methods. The patentable scope of this disclosure is defined by the claims, but may include other examples that would occur to a person skilled in the art. Such other examples are contemplated within the scope of the claims if they have structural elements that are not different from the literal language of the claims, or if they include equivalent structural elements that are not substantially different from the literal language of the claims.

Claims

1. A component comprising: Outer wall, the outer wall including an outer surface; At least one storage tank, the at least one storage tank being defined inside the outer wall and configured to receive cooling fluid therein; A coating system disposed on the outer surface, the coating system having a thickness; and A plurality of adaptive cooling openings are defined in the outer wall. Each adaptive cooling opening extends outward from a first end in flow communication with the at least one storage tank through the outer surface to a second end, the second end covering at least a portion of the thickness of the coating system. At least one of the adaptive cooling openings is oriented at an acute angle relative to a direction perpendicular to the outer wall. The plurality of adaptive cooling openings include a group of adaptive cooling openings arranged in a certain manner, wherein each of the adaptive cooling openings in each group is rotated at an acute angle in a direction different from the other adaptive cooling openings in the group.

2. The component of claim 1, wherein the second end is defined at the outer surface and covers the entire thickness.

3. The component of claim 1, wherein the second end is defined in the coating system and covers the coating system at a depth less than the thickness, such that the adaptive cooling opening partially extends into the coating system.

4. The component of claim 3, wherein the coating system comprises an adhesive layer and at least one additional layer, the adhesive layer being adjacent to the outer surface, and the second end being disposed within the at least one additional layer.

5. The component according to claim 4, wherein the at least one additional layer comprises an intermediate layer and an outer layer, and the second end is disposed within the outer layer.

6. The component according to claim 1, further comprising: An inner wall defined inside the outer wall, the inner wall including a hole defined therein and extending through therethrough, the at least one storage slot defined inside the inner wall; and At least one chamber is defined between the inner wall and the outer wall, and the orifice is configured to guide an impinging jet of the cooling fluid from the at least one storage tank through the at least one chamber toward the outer wall, the first end being coupled to the at least one chamber in flow communication.

7. The component of claim 1, wherein the first end is coupled to the channel in a flow communication manner, the channel extending substantially parallel to the outer surface within the outer wall, and the channel being in flow communication with the at least one storage tank.

8. The component of claim 1, wherein the cross-sectional area of ​​the adaptive cooling opening decreases substantially between the first end and the second end.

9. A rotating machine, comprising: The burner section is configured to generate combustion gases; The turbine section is configured to receive the combustion gases from the combustor section and thereby generate mechanical rotational energy, wherein the path of the combustion gases through the rotating machine defines a hot gas path; and The component near the hot gas path includes: Outer wall, the outer wall including an outer surface; At least one storage tank, the at least one storage tank being defined inside the outer wall and configured to receive cooling fluid therein; A coating system, wherein the coating system is disposed on the outer surface, the coating system having a thickness; and A plurality of adaptive cooling openings are defined in the outer wall. Each adaptive cooling opening extends outward from a first end in flow communication with the at least one storage tank through the outer surface to a second end, the second end covering at least a portion of the thickness of the coating system. At least one of the adaptive cooling openings is oriented at an acute angle relative to a direction perpendicular to the outer wall. The plurality of adaptive cooling openings include a group of adaptive cooling openings arranged in a certain manner, wherein each of the adaptive cooling openings in each group is rotated at an acute angle in a direction different from the other adaptive cooling openings in the group.

10. The rotating machine of claim 9, wherein the outer wall is formed of either a metal alloy or a ceramic matrix composite material.

11. The rotating machine of claim 9, wherein the turbine portion comprises a plurality of rotor blades and a plurality of stator blades, the component comprises one of the rotor blades and the stator blades, and wherein the plurality of adaptive cooling openings are disposed on the leading edge of the component.

12. The rotating machine of claim 9, wherein the at least one adaptive cooling opening is oriented such that the second end is at least partially tilted in the local direction of the working fluid flow above the outer wall, such that the at least one adaptive cooling opening is configured to guide the cooling fluid from the second end with a velocity component opposite to the local direction of the working fluid flow.

13. The rotating machine of claim 9, wherein the second end is defined at the outer surface and covers the entire thickness.

14. The rotating machine of claim 9, wherein the second end is defined in the coating system and covers the coating system at a depth less than the thickness, such that the adaptive cooling opening extends partially into the coating system.

15. The rotating machine of claim 9, further comprising an auxiliary compressor upstream of the component, the auxiliary compressor being configured to increase the pressure of the cooling fluid supplied to the at least one storage tank in response to an additional flow rate of the cooling fluid required to supply the adaptive cooling opening in the spalling region of the component.

16. A method for manufacturing a component, the method comprising: An outer wall is formed to enclose at least one storage tank, the at least one storage tank being configured to receive cooling fluid therein, the outer wall including an outer surface and a plurality of adaptive cooling openings defined in the outer wall, at least one of the plurality of adaptive cooling openings being oriented at an acute angle relative to a direction perpendicular to the outer wall, wherein the plurality of adaptive cooling openings includes a group of adaptive cooling openings arranged in a certain manner, and wherein each of the adaptive cooling openings in each group is rotated at the acute angle in a direction different from the other adaptive cooling openings in the group; as well as A coating system is disposed on the outer surface, the coating system having a thickness, wherein each of the adaptive cooling openings extends outward from a first end in flow communication with the at least one storage tank through the outer surface to a second end, the second end covering at least a portion of the thickness of the coating system.

17. The method of claim 16, further comprising: At least once before and during the application of the coating system to the outer surface, the cover is deployed at the second end of the adaptive cooling opening, wherein applying the coating system to the outer surface includes applying the coating system around and above the cover.

Images