Acoustic Breakthrough Detection in Dual-Wall Components
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Solution Overview
Problem
In the fabrication of components for gas turbine engines, existing methods struggle to accurately detect breakthrough during the formation of thin film cooling holes in dual-wall components, particularly when the backside is difficult to access, leading to potential damage and inefficiencies.
Innovation Solution
The technique involves creating a pressure differential between the interior and exterior of the dual-wall component, using acoustic monitoring to detect breakthrough by listening for acoustic signals such as a whistle, and automatically ceasing the fabrication process to prevent damage, while also allowing for precise control of hole formation based on the acoustic signal characteristics.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If acoustic monitoring is used to detect breakthrough, then measurement precision is improved, but device complexity increases
Solution Approach 1:
The patent replaces complex mechanical breakthrough detection systems with acoustic monitoring. Instead of using mechanical sensors or visual inspection systems on the backside, the invention uses acoustic sensors to listen for the characteristic sound of breakthrough, substituting mechanical complexity with acoustic field measurement.
Solution Approach 2:
The patent introduces acoustic waves as an intermediary medium to detect breakthrough. The acoustic sensor captures sound waves generated during the drilling process, using the acoustic field as a mediator to transmit breakthrough information from the drilling location to the detection system without requiring direct mechanical contact or visual access to the backside.
2Measurement precision
If pressure differential is created for acoustic signal enhancement, then measurement precision is improved, but use of energy increases
Solution Approach 1:
The patent applies preliminary action by establishing the pressure differential before the breakthrough detection is needed. The pressurization of the second wall cavity is performed in advance, so that when breakthrough occurs, the acoustic signal is immediately enhanced without requiring additional energy input at the moment of detection.
Solution Approach 2:
The patent employs periodic action through pulsed pressurization or intermittent monitoring cycles. Instead of maintaining continuous high pressure, the system applies pressure in periodic cycles, reducing average energy consumption while still achieving sufficient acoustic signal enhancement during critical detection periods.
3Reliability
If automatic cessation of fabrication is implemented, then reliability is improved, but device complexity increases
Solution Approach 1:
The patent implements feedback control where the acoustic sensor continuously monitors the drilling process and provides real-time feedback to the control system. When the characteristic breakthrough sound is detected, the feedback signal automatically triggers cessation of the fabrication process, creating a closed-loop control system that prevents damage without requiring complex manual intervention systems.
Solution Approach 2:
The system performs self-service by using its own acoustic monitoring capability to automatically detect breakthrough and trigger process cessation. The fabrication system monitors itself through acoustic sensors and autonomously stops when breakthrough occurs, eliminating the need for external monitoring equipment or manual inspection.
4Ease of operation
If acoustic monitoring enables breakthrough detection without backside access, then ease of operation is improved, but measurement precision may worsen
Solution Approach 1:
The patent uses acoustic waves as an intermediary that can penetrate and carry information from locations that are difficult to access directly. The acoustic sensor captures sound waves that travel through the material and air gaps, providing breakthrough detection capability without requiring physical access to the backside, thus maintaining both ease of operation and measurement precision.
Solution Approach 2:
The patent replaces mechanical access requirements with acoustic field measurement. Instead of requiring physical contact or visual inspection of the backside, the system uses acoustic sensors that can detect breakthrough sounds through air gaps and material structures, substituting mechanical access constraints with non-contact acoustic detection.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This method enables accurate detection of breakthrough without visual or physical access to the backside, reducing damage and improving the surface finish and efficiency of hole formation, allowing for faster fabrication and precise control of hole diameter and geometry.
Implementation Method 1
acoustically monitoring the hole fabrication, detecting breakthrough of the first wall of the dual-wall component based on an acoustic signal due to gas passing through the fabricated hole
Implementation Method 2
creating a pressure differential between the interior of the dual-wall component and the exterior of the dual-wall component
Data Source
AI summary
Disclosed techniques include creating a pressure differential within an interior of a dual-wall component relative to pressure at an exterior of the dual-wall component, fabricating a hole in a first wall of the dual-wall component, while fabricating the hole in the first wall of the dual-wall component, acoustically monitoring the hole fabrication, while acoustically monitoring the hole fabrication, detecting breakthrough of the first wall of the dual-wall component based on an acoustic signal due to gas passing through the fabricated hole, and based on the acoustic signal, ceasing the fabrication of the hole.