Turbine component with aerogel section and reinforcement mechanism, and related method of manufacturing the same

Abstract

A turbine component (1) is provided comprising an airfoil (2) with a hybrid material, wherein the hybrid material comprises an aerogel section (3), and a reinforcement (4) for mechanically stabilizing the airfoil (2), wherein the reinforcement (4) connects a root section (5) of the component (1) with the aerogel section (1), wherein the connection is established via an interlock (6) or form fit. Moreover, a method of manufacturing the turbine component (1) is presented, the method comprising the steps, (i) initially simulating a stress distribution in the component with a finite element analysis, (ii) based on the simulation result, identifying a direction of highest stresses, and (iii) manufacturing an aerogel (3) block of the component (1), wherein reinforcement fibers (12) are arranged according to the identified direction of highest stress.

Description

[0001] 2024 PF00819

[0002] Description

[0003] Turbine component with aerogel section and reinforcement mechanism, and related method of manufacturing the same

[0004] The present invention relates to a turbine component comprising an airfoil with a hybrid material, wherein the hybrid material comprises an aerogel section and a reinforcement mechanism. Additionally, the present application comprises a method of manufacturing the component .

[0005] Preferably, the component denotes a component of a turbo machine, e . g . applied in the flow path hardware of a gas turbine, like a blade, a vane, a swirler, or a burner component . In the alternative, the component may pertain to a high-performance component , such as a component applied in power generation, in the aviation or the automotive industry.

[0006] Additive manufacturing (AM) or 3D-printing techniques comprise e . g . powder-bed-fusion methods , such as selective laser melting (SLM) or laser powder bed fusion (LPBF) , selective laser sintering (SLS ) and electron beam melting (EBM) .

[0007] A method of 3D printing of graphene-based aerogels is described in the article "3D printing of graphene-based aerogels and their applications" of "FlatChem" volume 47 , September 2024 , 100731 of the authors

[0008] Jiaying Wang, Zhe Shi, Jiani Gong, Xianglin Zhou, JiamingLi , Zhiyang Lyu, for example . Therein, "aerogels" are described as extraordinarily lightweight and porous functional materials which gained significant interest in academia and industry over the past decades . Graphene-based aerogels in particular stand out due to their excellent conductivity properties , high specific surface area, and efficient adsorption efficiency. Despite these advantageous properties , aerogels face challenges in mechanical durability,2024 PF00819

[0009] complicating their processing, especially in applications requiring complex structures . 3D printing technology holds promise for overcoming these limitations through its capabilities in microscale manufacturing, rapid prototyping, and arbitrary shaping . The article summarizes the advantages of graphene-based aerogels and compares various 3D printing techniques used for aerogel fabrication . Furthermore, it also highlights the energy and environmental applications of 3D-printed graphene and graphene-based composite aerogels .

[0010] Moreover, a method of preparing an aerogel precursor, and a carbon aerogel is described e . g . in US 11 , 203 , 003 B2 , for instance .

[0011] In general additive manufacturing has proven to be useful and advantageous in the fabrication of prototypes or complex components , such as components with filigree structure or functionally cooled components . Further, the additive manufacture stands out for its short chain of process steps which in turn enables material economization and a particularly low lead time .

[0012] The present invention actually tackles various technical issues or challenges connected to today' s turbine components and its applications for ( stationary) gas turbines . As will be outlined in greater detail below by way of a problem and solution description, the invention relates to the use of an aerogel for the airfoil or turbine component and as well as a reinforcement or anchoring mechanism which accounts for the required mechanical stabilizing . As a third aspect , a method of manufacturing of a related turbine component is provided .

[0013] The common technical problem and related problem solution addressed by the invention is the need for a turbine blade material that combines high strength, lightweight properties , (heat) resistance, and an easy manufacturability with low boundary conditions .2024 PF00819

[0014] Traditional turbine blade materials often face limitations in terms of weight, strength, thermal insulation, and the ability to be precisely shaped . This invention aims to overcome these limitations by using a hybrid or composite material wherein an aerogel, known for its excellent insulation properties and lightweight nature, serves as a compound, like a matrix .

[0015] The aerogel may be anchored and / or reinforced with fibers of carbon, graphene, aramid, and / or glass which fibers are preferably aligned in the direction of the highest load during an intended operation of the related component .

[0016] Additionally, the ability to machine the aerogel block with CNC technology allows for the creation of turbine blades with complex geometries and precise dimensions , thereby enhancing performance, efficiency, and thermal resistance .

[0017] Likewise, an anchoring mechanism can be used, particularly for tackling an improved thermal insulation in high-temperature environments and hot-gas-exposure of the related component .

[0018] Another challenge is evidently a sufficient (thermo-) mechanical stability and durability . Thermal insulation materials like aerogels , though providing excellent thermal insulation, could be fragile and difficult to secure mechanically in a high-vibration, high-stress environment like a gas turbine engine .

[0019] Therefor the presented hybrid geometry uses another (metal) component for mechanically fastening and providing the required structural integrity, while the aerogel provides thermal insulation . The connection is made using an anchor or reinforcement that extends e . g . from a root or basis of the component into the aerogel part ensuring a secure and stable assembly.2024 PF00819

[0020] 4

[0021] Currently, there are approached which solve the above-listed challenges only partly .

[0022] One of the most advanced solutions for turbine blade material is , e . g . , the use of single crystal metal blades . These parts are made from superalloys , typically nickel-based, and are designed to have a single crystal structure . This means that the entire blade is composed of a single, continuous crystal lattice, with (almost) no grain boundaries or imperfections . These structures stand out for high strength . The absence of grain boundaries eliminates weak points , and significantly enhances the mechanical strength of the related blade, vane or shroud .

[0023] Also, single crystal blades exhibit excellent resistance to creep (deformation under high stress and temperature) , which is crucial for turbine components operating in extreme conditions .

[0024] Single crystal materials further excel in thermal fatigue resistance . Uniformity of the crystal structure improves resistance to thermal fatigue and extends the component ' s operational life .

[0025] However, there are also challenges which go along with the manufacture . For instance, there are very high cost; the production of single crystal blades is extremely expensive due to the complex manufacturing process and the high cost of related raw materials . To that effect, there is only a low production yield . The related manufacturing process of single crystal blades by casting has hence a very low yield only, meaning that a significant proportion of blades may be rej ected due to defects . Inherently, the solidification process and its control to ensure a single crystal structure is highly challenging . It requires precise temperature control and specialized equipment, making the process difficult to scale .2024 PF00819

[0026] 5

[0027] Depending on the application and performance requirements , also polycrystalline superalloys are conventionally used, which consist of multiple crystal grains . Often These materials are also nickel-based and are widely used in turbine blades and provide good mechanical properties in principle .

[0028] Particularly, polycrystalline superalloys offer a good balance of strength, toughness , and resistance to high temperatures . Further, the production techniques for polycrystalline superalloys are well-established and more cost-effective as compared to single crystal blades .

[0029] Challenges , however, pertain to grain boundary weaknesses . The presence of grain boundaries can function as initiation points for cracks and other failures , reducing the overall durability of the blade . Consequently, such a structure only shows limited creep resistance . Although this being better than for many other materials , polycrystalline superalloys do not match the creep resistance of single crystal blades .

[0030] Anyway, current material solutions often also involve the use of insulation materials or coatings in combination with metal substrates to enhance the performance of turbine blades .

[0031] Coatings have proven to improve resistance to oxidation, corrosion, and thermal degradation . So-called thermal barrier coatings (TBC) , e . g . , improve the thermal resistance of the blades , allowing them to operate at higher temperatures .

[0032] Ceramic TBCs have e . g . been widely used to protect metal components from high temperatures . These coatings are applied to turbine blades , combustors , and other hot section components to reduce heat transfer and protect the underlying metal . Air cooling techniques , such as film cooling and convective cooling, have been further employed to manage heat dissipation off the turbine parts .2024 PF00819

[0033] 6

[0034] Coatings , however, bring in another complexity, i . e . inherent adhesion issues to some degree . Ensuring strong adhesion between the coating and the metal substrate can be challenging, and poor adhesion can lead to coating delamination . The application of coatings , in turn, requires specialized equipment and processes , adding to the overall manufacturing complexity and cost .

[0035] While coatings can enhance surface properties , they do not fundamentally improve the structural properties of the underlying metal .

[0036] Hence there is need for a new general solution . Given the limitations of existing materials and methods , the presented approach clearly provides a solution, and it is an obj ect of the present invention to combines the best properties of high strength, light weight , heat resistance, and manufacturability with good design freedom.

[0037] The mentioned obj ect is achieved by the subj ect-matters of the independent claims . Advantageous embodiments are subj ectmatter of the dependent claims .

[0038] An aspect of the present invention relates to a turbine component comprising an airfoil with a hybrid or composite material, wherein the hybrid material comprises at least one aerogel section, and a reinforcement mechanism for mechanically stabilizing the airfoil or aerogel, wherein the reinforcement mechanism connects a (metallic) root section of the component with the aerogel or airfoil section, wherein the connection is established and the aerogel and the further composite , e . g . metal parts , are attached via a form fit or interlock, interlocking the composite elements of the hybrid material .

[0039] This interlocking design ensures a precise and secure fit between the aerogel and metal components , enhancing the overall stability and integrity of the hybrid structure . The2024 PF00819

[0040] 7

[0041] form fit mechanism also facilitates an easier assembly and disassembly, which can be beneficial for maintenance and repair .

[0042] As an advantages , the aerogel is significantly lighter than metal superalloys , reducing the overall weight of the turbine component . This leads to improved turbine efficiency and reduced mechanical stress on the components . Also, it particularly brings about a far enhanced thermal insulation, as the aerogel provides superior thermal insulation compared to metals , which helps in maintaining the structural integrity of the blade at high temperatures .

[0043] The invention reinforcement or anchoring of the aerogel (matrix) , such as with high-strength fibers aligned in the required direction significantly enhances the tensile strength of the aerogel, making the composite material capable of withstanding high mechanical stresses .

[0044] The reinforcement or anchoring mechanism is preferably configured such that it accommodated highest tensile loads during service of the component and ensures effective load distribution, reducing the risk of material failure .

[0045] The aerogel section can favorably be machined using CNC technology to create turbine blades with complex geometries and precise dimensions . Hence, also precise manufacturability is achievable , and CNC machining allows for the creation of turbine blades with intricate designs and precise dimensions , enhancing aerodynamic performance and efficiency. CNC, i . e . Computerized Numerical Control, technology even enables the production of customized blade designs tailored to specific performance requirements , improving overall turbine efficiency by design . Still further, the use of CNC machining and scalable manufacturing processes for the aerogel composite material can reduce production costs compared to the expensive and low-yield processes required for single crystal metal blades .2024 PF00819

[0046] 8

[0047] In other words , the inventive composite airfoil advantageously combines the thermal insulation properties of aerogel with the thermal stability of high-performance fibers or metal composites .

[0048] Yet, the aerogel airfoil can also be coated with ceramics for extra heat resistance . Optional coating the aerogel airfoil with ceramics further enhances its heat resistance , providing an additional thermal barrier that protects the blade from excessive temperatures .

[0049] The aerogel ' s inherent thermal insulation properties , combined with the thermal stability of the reinforcing fibers , provide excellent heat resistance . This allows the turbine blades to operate at higher temperatures without degradation .

[0050] In addition to or in the alternative of using the above-mentioned fiber reinforcement, the inventive hybrid geometry makes use of metallic components . While the hot sections are made of aerogel, which is less prone to cracking compared to ceramic coatings , can withstand very high temperatures and is extremely lightweight, the mechanically stressed parts are made of metal . Accordingly, the invention achieves mechanical stability through a combination of metal parts for strength and aerogel parts for thermal insulation, connected via an anchoring mechanism. The aerogel ' s superior thermal resistance and the robust anchoring mechanism between aerogel and metal parts may result in longer-lasting components with reduced maintenance needs .

[0051] By addressing these key differences , the proposed invention offers a more efficient, lightweight , and durable solution for high-temperature applications such as turbine blades , while also simplifying the manufacturing process and reducing costs .2024 PF00819

[0052] In an embodiment, a shape, cross-section or circumference of the airfoil is solely defined by the aerogel . To this effect design freedom of an (additive) manufacturing process of the aerogel can be fully exploited for designing shape and aerodynamic properties of the part .

[0053] In an alternative embodiment, the airfoil additionally comprises a metallic section defining part of the airfoil shape, wherein the airfoil is arranged at locations which e . g . face high thermal load or at hotspots during the intended operation of the part . This might be the case particularly at the leading edge of an airfoil or blade .

[0054] Accordingly, thermal load can advantageously be reduced, while maintaining low weight of the component .

[0055] Similarly, the metallic section preferably encompasses regions requiring specific mechanical stabilization or fastening during the turbine component' s service . According to these embodiments , a true disruptive or hybrid approach for turbine components is achieved .

[0056] The hybrid material or composite airfoil includes in one embodiment an (air) gap or interspace between the different material sections , particularly between the aerogel section and the metallic section, which preferably accommodates thermal expansion of or between the (hybrid) material constituents thereby reducing thermal stress amongst the different material phases . Different materials have usually different thermal expansion rates , which can cause stress and potential failure at the interfaces between materials .

[0057] The above-described reinforcement may be provided by the anchoring mechanism as described, wherein the anchoring mechanism comprise at least one anchoring rod, preferably two or more anchor rods which extend through the aerogel section (cf . below) . Such a design particularly enables good balancing of thermal and mechanical requirements of the component .2024 PF00819

[0058] 10

[0059] In an embodiment, the airfoil comprises cooling channels extending through the aerogel section, wherein the cooling channels are connected to the at least one, preferably two, anchoring rots , i . e . the anchoring mechanism. According to this embodiment, heat can effectively be conducted within the component , i . e . towards and away from the anchoring rod .

[0060] According to another embodiment , the hybrid material (component) comprises reinforcement fibers for the reinforcement , wherein the reinforcement fibers are oriented in the aerogel section as a matrix according to a direction of highest expected tensile and / or compressive stresses , loads or strains . The reinforcement fibers may e . g . be made of graphene, carbon, aramid and / or glass , bringing about the related material mechanical properties and specific merits .

[0061] Gas turbine engines , especially in the combustion and turbine sections , operate at very high temperatures . These temperatures can evidently degrade materials , cause damage to components , and reduce efficiency. To this effect, according to another embodiment of the component, it comprises an insulation assembly, wherein the insulation assembly in turn comprises a heat shield layer and a thermal absorption layer with a so-called phase change material . This embodiment advantageously absorbs and manages heat, preventing the temperature of the fluid or substrate on the insulated side from exceeding critical levels .

[0062] At the same time, material degradation can advantageously be prevented . High temperatures can cause lubrication oils , fuels , and other fluids to degrade, leading to coking, chemical transformations , and reduced performance . Hence, the phase change material in the thermal absorption layer absorbs heat during high-temperature conditions , preventing the fluid from reaching degradation temperatures .2024 PF00819

[0063] 11

[0064] The mentioned insulation assembly can be configured as an insulation tube layer or cover rendering it broadly applicable and versatile for various applications such as lubrication oil tubes , fuel lines , and protective layers for engine controllers and other components .

[0065] In an embodiment, the turbine component comprises a ceramic thermal barrier coating additionally applied to the airfoil .

[0066] In a preferred embodiment, the turbine component is a blade or vane of a stationary gas turbine .

[0067] As mentioned above single crystal metal blades have a fixed crystal orientation that is unidirectional . This means that the crystal structure is aligned in a single direction, which may not always coincide with the direction of the maximum tensile or compressive stresses experienced by the component during operation .

[0068] The fixed orientation can hence lead to suboptimal performance because the material ' s strength is not fully utilized in the directions where the highest stresses occur . This misalignment can in turn result in increased risk of material failure and reduced operational lifespan .

[0069] Further, the ability to customize the material properties to match the specific stress distribution patterns of different turbine components is limited for single crystal structures .

[0070] Hence, s further aspect of the present invention relates to a method of manufacturing the described turbine component . The method comprises the steps of i ) initially simulating a stress distribution in the component , such as simulating material properties , thermal loads , mechanical loads and analyzing stress and strain, with a finite element analysis .

[0071] The method further comprises , ii) , based on the (initial) simulation result, identifying or specifying a direction2024 PF00819

[0072] 12

[0073] and / or a position of highest (tensile and compressive) stresses .

[0074] Also, the method comprises in iii) , manufacturing an aerogel section of the component, wherein reinforcement fibers are arranged and / or generated or printed according to the identified direction of highest stress .

[0075] As a particular advantage of the method, material use can be economized; by reinforcing only the areas that experience the highest stresses , the invention optimizes material use , ensuring that high-strength fibers are only placed where they are needed most .

[0076] In an embodiment, the method applies iv) a subsequent simulation which may be of the same type as the initial one , wherein - according to results of the subsequent simulation -at least the aerogel section of the component is remanufactured (re-3Dprinted) with an adj usted reinforcement fiber alignment or fiber orientation . Such iterative adj ustments advantageously lead to full exploitation of the method' s capacity.

[0077] The method may further comprise (CNC) machining of the aerogel section in v) such that a form fit of the aerogel together with a metallic anchoring structure is achieved, or vice versa .

[0078] Also, the root section of the component may be established by conventional casting together with an anchor rod which accommodate for tensile stress , wherein the anchor extends from a root section into the aerogel section thereby ensuring a secure and stable assembly.

[0079] As an advantage of the method, an inefficient material use can be prevented and using high-strength metals uniformly across the entire component, wherein only specific areas of the same require high-strength, avoided . In line with that,2024 PF00819

[0080] 13

[0081] high cost of the related expensive (metallic) materials can be averted .

[0082] Instead, the inventive method aims at an expedient reinforcement and hence uses an advanced simulation technique which facilitates identification and usage of material capacity at precise locations and directions of the highest stresses within the turbine component . Based on this analysis , an aerogel block is designed with fibers aligned specifically in these highly stressed areas .

[0083] Besides economizing cost ( cf . above) , possibly even the performance of the component per se can be increased by the intelligent hybrid and low weight material solutions which allow an improvement or aerodynamics and efficiency.

[0084] Evidently the method further facilitates customizing the fiber alignment specifically depending on an expected stress distribution in the component . This is particularly achieved as the alignment of the fibers is based on the related stress analysis , ensuring that fibers are aligned in the directions of maximum tensile and / or compressive stresses .

[0085] Hence, the invention enables an optimized resiliency of the material that is dependent on the expected load distribution . In other words , the customized fiber alignment ensures that the material ' s strength is fully utilized in the directions of maximum stress , minimizing stress concentrations and reducing the risk of material failure . The directional reinforcement significantly enhances the tensile and compressive strength of the aerogel block, improving its overall mechanical performance .

[0086] The presented integrative optimization loop particularly involves an initial simulation and manufacturing step, followed by subsequent simulations and adj ustments to the fiber alignment . This loop is preferably repeated until the stress distribution is fully optimized .2024 PF00819

[0087] 14

[0088] This iterative loop advantageously ensures that the material properties are continuously refined, leading to progressively better results with each iteration . It is even expected that the presented solution is superior to conventional approaches only after the first iteration, thereby already

[0089] providing immediate improvements in stress distribution and component lifespan .

[0090] The ability to additively manufacturing or 3D print the aerogel block or aerogel section brings about the inherent benefits of this technique over traditional manufacturing routes , like casting or forging of complex as expensive processes . The 3D printing capability particularly allows precise control over material properties and fiber alignment at high precision and good control over the material properties , resulting in a highly optimized component . The ability to customize the fiber alignment for each specific component provides greater flexibility in design and manufacturing, leading again to improved performance and efficiency .

[0091] 3D printing is further cost-effective and sustainable, thereby offering a scalable and cost-effective manufacturing process compared to the complex and expensive production of high-strength metals . At the same time the outstanding thermal insulation properties of the aerogel can be exploited .

[0092] The invention also relates to realizations comprising a combination of the features of several of the described embodiments .

[0093] Advantages and embodiments relating to the described composite turbine component and / or are valid or pertain likewise to the method of manufacturing the same and vice versa .2024 PF00819

[0094] 15

[0095] Turbo machines , particularly those for power generation purposes , are subj ect to steady development in order to increase efficiency. This development is actually gaining significance in view of restrictions which are to be implemented to comply with climate change and global warming mitigation . Further progress in turbine efficiency is e . g . complicated as operation temperatures of the hot gas path of gas turbines , would yet have to be increased . At the same time there is a stringent demand to apply the turbo machines in a less steady operational mode, e . g . on demand in 'peaker' plants when there is a high demand for electricity, for example . This poses significant challenges particularly for the materials applied in the given machines , as for example the discontinuous (on demand) use highly increases material fatigue due to the involved warming and cooling cycles and therewith the number of the so-called "equivalent operating hours" . Thermo-mechanical fatigue and creep behavior are here the dominant issues which pose the main challenges for the turbo machine materials . All these challenges are expected to be at least partially tackled and solved by the merits of the present application as described herein .

[0096] Further, features and advantageous embodiments become apparent from the following description of the exemplary embodiment in connection with the Figures .

[0097] Figure 1 shows a simplified sketch of inventive airfoil of the turbine component in a perspective view .

[0098] Figure 2 shows a simplified schematic of the inventive turbine component according to an alternative embodiment .

[0099] Figure 3 shows a simplified schematic of the inventive turbine component according to yet another embodiment .

[0100] Figure 4 shows a simplified flowchart indicating steps of the inventive manufacturing method .2024 PF00819

[0101] 16

[0102] Figure 5 indicates a fiber alignment according to the presented manufacturing method .

[0103] Figure 6 further indicates details of the turbine component manufactured according to the inventive method .

[0104] Like elements , elements of the same kind and identically acting elements may be provided with the same reference numerals in the Figures . The Figures are not necessarily depicted true to scale and may be scaled up or down to allow for a better understanding of the illustrated principles . Rather, the described Figures are to be construed in a broad sense and as a qualitative base which allows a person skilled in the art to apply the presented teaching in a versatile way .

[0105] The term „and / or" as used herein shall mean that each of the listed elements may be taken alone or in conj unction with two or more of further listed elements .

[0106] Figure 1 shows an airfoil section of the inventive turbine component in a simplified perspective view .

[0107] The inventive turbine component 1 basically comprises the indicated airfoil 2 with a hybrid material, that is an aerogel section 3 , and a reinforcement means 4 for mechanically stabilizing the airfoil 2 , wherein a mechanism of the reinforcement 4 preferably connects a root section 5 (not explicitly indicated in Figure 1 ; cf . Figures 2 onwards ) of the component 1 with the aerogel section 3 , wherein the connection is established via an interlock 6 or form fit .

[0108] According to the simplified example of Figure 1 , the aerogel section 3 which actually defines also the shape of the airfoil 2 , is stabilized and reinforced by radially arranged reinforcement fibers 12 which extend from a root (not explicitly shown here) towards the tip section of the exemplified airfoil 2 .2024 PF00819

[0109] 17

[0110] The aerogel or aerogel section 3 shall essentially denote a highly porous solid material, such as made of silica, carbon, polymers , metal oxides , combinations thereof ; or further materials may be used as a basis to synthesize aerogels .

[0111] These structures which are further susceptible to be manufactured additively or by 3D printing, are known to have a dendritic structure with open pores which awards the material with excellent thermal insulation properties .

[0112] It is particularly shown in Figure 1 that it is solely the aerogel section 3 which defines circumference and there with the aerodynamic properties of the airfoil 2 . The fibers 12 which may according to the invention e . g . be made of graphene, carbon, aramid and / or glass , are arranged in the interior of the aerogel section 3. Reference numeral 15 indicates the alignment direction of the fibers according to the vertical (radial) direction .

[0113] It is further shown that the reinforcement fibers 12 are oriented in the aerogel matrix 3 according to a direction of highest expected tensile stress during the intended operation of the turbine component 1 . In the example shown, said highest stresses might particularly occur in the radial direction according to which the fibers 12 are oriented or extended .

[0114] Even though this is not explicitly indicated in Figure 1 , the fibers may be anchored, connected or interlocked to a root section of the component 1 which is not shown here .

[0115] Described in other words , the anchoring by fiber reinforcement excels in lightweight properties , as the aerogel 2 is significantly lighter than metal superalloys , reducing the overall weight of the turbine part . This leads to improved turbine efficiency and reduced mechanical stress . Moreover, a far enhanced thermal insulation can be provided as e . g . compared to metals , which supports the thermo-2024 PF00819

[0116] 18

[0117] structural resilience of a related blade at high temperatures .

[0118] An aerogel matrix with high-strength fibers aligned in the direction of the highest tensile load could significantly enhance the tensile strength of the aerogel matrix, making the composite material capable of withstanding high mechanical stresses . Still further, a load distribution may be customized and tailored according to a direction of the highest tensile load thereby reducing the risk of material failure .

[0119] In terms of manufacturability, the presented solution easily enables machining the aerogel block by using CNC technology to create turbine blades with complex geometries , intricate design, cooling channels and thin wall dimensions .

[0120] Consequently, the composite design allows for the creation of turbine blades with enhanced aerodynamic performance and efficiency. CNC technology particularly enables the production of customized blade designs tailored to specific performance requirements , improving overall gas flow efficiency .

[0121] Simultaneously, the use of CNC machining and scalable manufacturing processes for the aerogel composite material can reduce production costs compared to the expensive and low-yield processes required for single crystal metal blades , for instance .

[0122] The present invention hence combines the thermal insulation properties of aerogel 3 with the thermal stability of high-performance fibers . The aerogel airfoil can, in addition, also be coated with ceramics for extra heat resistance yielding in a yet improved thermal insulation . Coating the aerogel airfoil 2 with ceramics e . g . further enhances its heat resistance, providing an additional thermal barrier that protects the blade 1 from extreme temperatures .2024 PF00819

[0123] 19

[0124] Figure 2 shows another embodiment of an inventive turbine component 1. The component 1 comprises a root section 5 and, on top of it, the airfoil section 2 comprising the aerogel 3 and an anchoring mechanism 10. The anchoring mechanism 10 comprises two anchoring rods which are likewise arranged and configured to stabilize the aerogel section 3 mechanically. The root section 5 is preferably a conventional root section made of a metallic material, such as a superalloy.

[0125] The rods 10 may serve a similar purpose as the fibers 12 as shown in Figure 1 and, to this effect, constitute an equivalent means of reinforcement for the airfoil 2 and / or the aerogel 3 . In other words , the reinforcement - provided by the shown anchoring mechanism - connects a root section 5 in the aerogel by a form fit or interlock 6. For an expedient interlock, at least one of the rods (cf . right one in the Figure) has a T-shaped distal end in order to hold the aerogel in place and connect it with the root 5.

[0126] Actually, the root section 5 may according to the invention be manufactured together with the anchoring rods 10.

[0127] Preferably, the root 5 may be conventionally cast along with the two anchors , wherein the anchor rods 10 serve for bearing the tensile stresses during the intended operation of the component 1 .

[0128] It is further shown in Figure 2 that the airfoil 2 may comprise cooling channels 11 which extend through the aerogel section 3 , wherein the cooling channels 11 are preferably connected to at least one of the anchor rods 10 or the anchoring mechanism. Without loss of generality, the course and location of the channels 11 may differ from the indication of Figure 2 . The cooling channels 11 may instead also be arranged according to an expected thermal load of the component in any preferred direction . More particularly, the cooling channels 11 may be implemented during the manufacturing process of the aerogel , such as manufactured or machined during the synthesis of the aerogel section 3 .2024 PF00819

[0129] 20

[0130] According to this embodiment (which may without loss of generality also hold for the other embodiments shown herein) , different material phases or sections , particularly those of the aerogel section 3 and a metallic section, like the anchors 10 , are preferably configured to accommodates thermal expansion of constituents of the hybrid material . This accommodation may particularly be facilitated by interspaces or an air gap as indicated by 9 in Figure 2 .

[0131] Described in other words , the anchoring functionality addresses the problem of managing high temperatures and mechanical stability in a hybrid structure by utilizing the unique properties of aerogel and metal . Actually, the invention employs a hybrid geometry where the hot sections are made of aerogel, which can withstand very high temperatures and is extremely lightweight . This reduces the thermal load on the structure and improves thermal insulation .

[0132] The parts that require mechanical fastening are made of metal, which provides the necessary mechanical strength and durability. This ensures that the structure can handle mechanical stresses and loads effectively .

[0133] A rigid and reliable mechanical connection between the aerogel and metal parts is meanwhile achieved through the anchoring functionality. This anchor extends from the root metal part into the aerogel part 3 , ensuring a secure and stable connection between the two different materials . This design feature ensures that the hybrid structure maintains its integrity under various operating conditions . By utilizing a simpler metal geometry in particular, the casting yield could be significantly increased . This means that the manufacturing process becomes more efficient, reducing waste and improving the overall production rate as well . The simpler geometry also contributes to easier and more cost-effective manufacturing .2024 PF00819

[0134] 21

[0135] The aerogel and metal parts can be attached using a mechanical form fit . Such an interlocking design ensures a precise and secure fit between the aerogel and metal components , enhancing the overall stability and integrity of the hybrid structure . The form fit mechanism also facilitates easier assembly and disassembly, which can be beneficial for maintenance and repair .

[0136] By combining these technical features , the invention effectively manages high temperatures with the thermal insulation properties of the aerogel while maintaining mechanical stability and strength via the solid metal components . This hybrid approach hence leverages the best properties of both material constituents to solve the problem of creating a structure that can withstand high temperatures and mechanical stresses , while also improving manufacturing efficiency through a simpler metal geometry.

[0137] Figure 3 shows yet another embodiment of the present invention according to which an exterior part of the airfoil is formed of a metallic section . This metallic section is indicated in Figure 3 with reference 7 . As shown in the Figure, the metallic section 7 may form an integral part of the airfoil and define part of its outer shape, like in the present example, the middle portion and a trailing edge portion (not explicitly indicated) of the airfoil 2 .

[0138] Generally, also this metallic portion serves for the 'anchoring' or stabilizing of the aerogel 3 and the root section 5 . While the metallic section 7 , encompasses regions requiring specific mechanical stabilization ( cf . middle section and trailing edge) , the aerogel 3 is arranged at hot spots or locations 8 which face high thermal load during an operation of the turbine component 1 , like at the leading edge of the airfoil 2 .2024 PF00819

[0139] 22

[0140] As indicated by the form fit or interlock elements 6, the aerogel section 3 and the metallic section 7 is expediently connected and fixed for a sufficient mechanical stability during operation of the component 1.

[0141] The turbine component 1 or part of it, such as only the airfoil 2 or a part of the airfoil may comprise or constitute insulation assembly 13 , wherein the insulation assembly 13 in turn comprises a heat shield layer and a thermal absorption layer with a phase change material (not explicitly indicated) . For instance, said insulation assembly 13 may be configured as an insulation tube, layer or cover thereby making it e . g . versatile for various applications , such as lubrication of oil tubes , fuel lines and protective layers for engine controllers and other components .

[0142] Figure 4 illustrates basic inventive method steps by way of a simplified flowchart . The inventive method is a method of manufacturing the turbine component according to one of the previous claims comprising, (i) initially simulating a stress distribution in the component 1 with a finite element analysis .

[0143] The method further comprises (ii) identifying a direction of highest stresses based on the simulation result, and furthermore, (iii) manufacturing an aerogel block of the component 1 , wherein the reinforcement fibers 12 are arranged according to the identified direction 15 of highest stress .

[0144] The method may further comprise an optional step ( iv) of a subsequent simulation being carried out, wherein according to results of the subsequent simulation, the aerogel section 3 is re-manufactured with an adj usted reinforcement fiber orientation .

[0145] According to optional method step (v) the method, the aerogel section is CNC machined such that a form fit 6 of the aerogel2024 PF00819

[0146] 23

[0147] together with a metallic anchoring structure can be achieved .

[0148] Figure 5 indicates by way of a simple turbine blade design the alignment of reinforcement fibers 12 relative to the turbine blades shape, wherein the fibers 12 are preferably aligned according to locally varying directions of highest (expected) tensile stresses during an intended operation . Particularly, said fibers 12 may be arranged radially (cf . upper part) ; wherein a reasonable number of fibers may as well be arranged according to a direction of flow approaching the leading edge of the component (cf . fibers at the bottom left of the airfoil for instance) .

[0149] Figure 6 indicates similarly to Figure 2 component design with a pre-manufactured root 5 which may be cast together with the anchoring mechanism, consisting of two anchoring rods 10. The aerogel section 3 and the complementary metal structure are preferably attached and rigidly linked via the described form fit 6 but still in a way that thermal stresses can be accommodated between the two different material phases . It is particularly shown here that the anchoring rods 10 are - while extending through the aerogel section 3 -rigidly fixed or interlocked to the root 5.

[0150] In addition to the indication of Figure 2 , here as well the described fiber reinforcement is applied in an inventive embodiment as a supplemental measure of mechanical stabilization .

[0151] The inventive method and its advanced simulation technique may be described or paraphrased in other words following :

[0152] The method preferably deploys a Finite Element Analysis ( FEA) . The process begins with simulating the high-temperature turbine component 1 using FEA. This simulation accounts for thermal loads , mechanical loads , and material properties to provide a detailed analysis of the stress and strain within the component . By way of a stress analysis , the2024 PF00819

[0153] 24

[0154] FEA results are used to identify the direction and position of the highest tensile stresses . This precise stress analysis is crucial for designing the reinforcement strategy.

[0155] The process comprises an initial simulation to determine the optimal fiber alignment, followed by 3D printing the aerogel block with the specified fiber orientation . After the initial manufacturing, a new simulation may be performed on the 3D printed aerogel block to confirm the stress distribution and identify any areas for further optimization .

[0156] The advanced simulation technique particularly stands out for an accurate stress mapping with which a detailed analysis of the stress distribution within the turbine component is achieved; thereby ensuring that the reinforcement fibers are aligned in the exact directions of maximum expected load .

[0157] As a particular merit of this step, an optimized load distribution is accounted for in the mechanical design and specification .

[0158] The customized fiber alignment ensures that the material ' s strength is fully utilized where it is needed most , minimizing stress concentrations and reducing the risk of material failure .

[0159] Additive manufacturing or the use of 3D printing technology allows for precise control over the material properties and fiber alignment, resulting in a highly optimized component that is tailored to the specific stress patterns of each case of application .

[0160] Based on the results of the subsequent simulations , (iterative) adj ustments can be made to the fiber alignment and the aerogel block is preferably reprinted . This iterative loop can then be repeated until the stress distribution is fully optimized . The iterative optimization loop ensures continuous improvements of the material properties , leading2024 PF00819

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[0162] to progressively better solutions with each iteration . Even after the first iteration, the solution is expected to be significantly better than a conventional approach .

[0163] Finally, the improved manufacturing of the component inevitably imparts the listed advantages to the component 1 thereby awarding it with a reduced weight , improved mechanical strength and thermal resistance . The lightweight properties of the aerogel matrix particularly reduce the overall mass of the component 1 , improving efficiency and reducing mechanical stress . As mentioned, the thermal insulation properties of an aerogel, combined with the optional ceramic coating, provide excellent thermal resistance, protecting the component 1 from high temperatures .

[0164] Preferably, the turbine component 1 is or is part of a blade or vane of a ( stationary) gas turbine .

[0165] The component as referred to herein may particularly relate to a part or an article of complex shape, such as with filigree portions of structures . Preferably, said component is made of a high-performance material, such as a material of great strength and / or thermal resistivity . Particularly, said part may constitute a part of a steam or gas turbine component , such as a blade , vane, shroud, shield, such as heat shield, tip, segment, insert, inj ector, seal, transition, burner, nozzle , strainer, orifice , liner, distributor, dome, boost, cone, lance, plate, resonator, piston or any corresponding retrofit kit . Alternatively, said component may relate to another or similar component .

[0166] The present solution overcomes the limitation of the previous solution available on the market and optimizes manufacturability, design, strength, (creep and oxidation) resistance and weight properties of the turbine component .2024 PF00819

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[0168] It will be obvious for a person skilled in the art that these embodiments and items only depict examples of a plurality of possibilities . Hence, the embodiments shown here should not be understood to form a limitation of these features and configurations . Any possible combination and configuration of the described features can be chosen according to the scope of the invention .

Claims

2024 PF0081927Claims1 . A turbine component ( 1 ) comprising an airfoil ( 2 ) with a hybrid material , wherein the hybrid material comprises :- an aerogel section ( 3 ) , and- a reinforcement mechanism ( 4 ) for mechanically stabilizing the airfoil ( 2 ) , wherein the reinforcement mechanism ( 4 ) connects a root section ( 5 ) of the component ( 1 ) with the aerogel section ( 1 ) , wherein the connection is established via an interlock ( 6 ) or form fit .2 . The turbine component ( 1 ) according to claim 1 , wherein a shape of the airfoil ( 2 ) is solely defined by the aerogel .3 . The turbine component ( 1 ) according to claim 1 , wherein the airfoil ( 2 ) additionally comprises a metallic section ( 7 ) defining part of an airfoil shape , wherein the aerogel is arranged at locations ( 8 ) which face high thermal load during an operation of the turbine component ( 1 ) , and wherein the metallic section ( 7 ) encompas se s regions requiring specific mechanical stabili zation .4 . The turbine component ( 1 ) according to claim 3 , wherein the hybrid material includes a gap ( 9 ) between dif ferent material sections , particularly between the aerogel section ( 3 ) and the metallic section ( 7 ) , which accommodates thermal expansion of the material .5 . The turbine component ( 1 ) according to one of the previous claims , wherein the reinforcement is provided by an anchoring mechanism ( 10 ) compri sing an anchor rod, preferably two anchor rods .6 . The turbine component ( 1 ) according to claim 5 , wherein the airfoil ( 2 ) compri ses cooling channel s ( 11 ) extending through the aerogel section ( 3 ) , wherein the cooling channels ( 11 ) are connected to the at least one anchor rod ( 10 ) .2024 PF00819287 . The turbine component ( 1 ) according to one of the previous claims , wherein the hybrid material comprises reinforcement fibers ( 12 ) , wherein the reinforcement f ibers ( 12 ) are oriented in the aerogel section ( 3 ) as a matrix according to a direction of highest expected tensile stres s of the turbine component ( 1 ) .8 . The turbine component ( 1 ) according to claim 7 , wherein the reinforcement fiber ( 12 ) is made of graphene , carbon , aramid and / or glas s .9 . The turbine component ( 1 ) according to one of the previous claims , comprising an insulation as sembly ( 13 ) , wherein the insulation as sembly ( 13 ) in turn comprises a heat shield layer and a thermal absorption layer with a pha se change material ( 14 ) .10 . The turbine component ( 1 ) according to claim 9 , wherein the insulation as sembly ( 13 ) is configured as an insulation tube , layer , or cover .11 . The turbine component ( 1 ) according to one of the previous claims , being a blade or vane of a stationary gas turbine .12 . A method of manufacturing the turbine component ( 1 ) according to one of the previous claims comprising the steps : - ( i ) initially simulating a stres s distribution in the component with a finite element analys is ,- ( ii ) ba sed on the simulation result , identifying a direction ( 15 ) of highe st stres s ,- ( iii ) manufacturing an aerogel block ( 3 ) of the component ( 1 ) , wherein reinforcement f ibers ( 12 ) are arranged according to the identified direction ( 15 ) of highe st stres s .2024 PF008192913 . The method according to claim 12 , wherein ( iv) a subsequent simulation is carried out , wherein according to results of the subsequent simulation , the aerogel section ( 3 ) is re-manufactured with an adj usted reinforcement fiber ( 12 ) orientation .14 . The method according to claim 12 or 13 , wherein the aerogel section is (v) machined such that a form f it ( 6 ) of the aerogel together with a metallic anchoring ( 10 ) structure is achieved .15 . The method according to one of claims 12 to 14 , wherein a root section ( 5 ) of the component ( 1 ) is cast with an anchor rod ( 10 ) , preferably two anchor rods , which accommodate tens ile stres ses , wherein the anchor extends from a root section ( 5 ) into the aerogel section ( 3 ) .

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