Adaptive Cover for Hot Gas Path Cooling

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Solution Overview

Problem

Hot gas path components in industrial machines often face temperature variations, leading to either insufficient cooling or excessive overcooling, which can result in stress, oxidation, and reduced efficiency due to the inability to adaptively manage heat distribution effectively.

Innovation Solution

The integration of an adaptive cover in the cooling pathway of hot gas path components, formed through additive manufacturing, which includes a heat transfer enhancing surface and intentional weakness regions, allowing the cooling pathway to open when the temperature exceeds a predetermined level, thereby optimizing cooling based on actual temperature conditions.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If conventional cooling pathways are used in hot gas path components, then cooling coverage is provided, but excessive overcooling occurs leading to reduced efficiency and increased energy consumption

Engineering Contradiction:

Improvecomponent reliabilityVSAvoidenergy loss due to overcooling

Core Design Contradiction:

ReliabilityVSLoss of energy

Solution Approach 1:

The cooling pathway transitions from a static, always-open configuration to a dynamic, temperature-responsive system. The adaptive cover remains closed under normal conditions to prevent overcooling, and automatically opens when temperature exceeds the predetermined threshold, allowing the system to adapt its cooling behavior based on real-time thermal conditions

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

The system changes the thermal parameter state by introducing a temperature-dependent control mechanism. The adaptive cover's thermal properties are designed such that it undergoes a state change at a specific temperature threshold, transitioning from a heat-blocking state to a heat-permissive state, thereby adjusting the cooling parameter dynamically

Inventive Principle:

Principle #35Parameter changes

2Temperature

If cooling pathways are always open, then adequate cooling is provided, but unnecessary cooling occurs reducing industrial machine output and efficiency

Engineering Contradiction:

Improvetemperature controlVSAvoidindustrial machine output

Core Design Contradiction:

TemperatureVSProductivity

Solution Approach 1:

The adaptive cover functions as a passive feedback mechanism that automatically responds to temperature conditions. When the temperature reaches the predetermined level, the cover opens to allow cooling; when temperature drops below the threshold, the cover closes to block cooling, creating a self-regulating feedback loop that optimizes both temperature control and productivity

Inventive Principle:

Principle #23Feedback

3Adaptability or versatility

If additive manufacturing is used to create adaptive covers, then complex geometries with heat transfer enhancing surfaces can be achieved, but manufacturing complexity increases

Engineering Contradiction:

Improveadaptive cooling capabilityVSAvoidcomponent complexity

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The adaptive cover integrates multiple functions into a single component: it serves as both a closure element for the cooling pathway and a heat transfer enhancement device through its integrated fin structures. The additive manufacturing process enables this merging by creating a monolithic structure that combines the cover body with attached fins, eliminating the need for separate components

Inventive Principle:

Principle #5Merging (Combining)

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 solution ensures that the cooling pathway opens only when necessary, reducing unnecessary cooling and preventing damage, thus enhancing the efficiency and longevity of hot gas path components by dynamically responding to temperature fluctuations.

Implementation Method 1

an adaptive cover in the cooling pathway at the outer surface, the adaptive cover configured to, in response to the high temperature reaching or exceeding a predetermined temperature of the adaptive cover, open the cooling pathway

Methodology Applied

Scientific EffectThermal conduction: Conduction (thermal)

Implementation Method 2

the adaptive cover including a heat transfer enhancing surface at the outer surface causing the adaptive cover to absorb heat faster than the outer surface

Methodology Applied

Scientific EffectHeat transfer enhancement through surface area increase: Conduction (thermal)

Data Source

PatentUS11041389B2Adaptive cover for cooling pathway by additive manufacture

Publication Date: 2021.06.22 GE INFRASTRUCTURE TECH LLC

AI summary

A hot gas path component of an industrial machine includes an adaptive cover for a cooling pathway. The component and adaptive cover are made by additive manufacturing. The component includes an outer surface exposed to a working fluid having a high temperature; an internal cooling circuit; and a cooling pathway in communication with the internal cooling circuit and extending towards the outer surface. The adaptive cover is positioned in the cooling pathway at the outer surface. The adaptive cover may include a heat transfer enhancing surface at the outer surface causing the adaptive cover to absorb heat faster than the outer surface.