Two-Piece Airfoil Baffle for Trailing-Edge Cooling Holes
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Solution Overview
Problem
Existing gas turbine engine baffles often lack cooling holes near the trailing edge of airfoil vanes due to manufacturing limitations, resulting in reduced cooling efficiency at this critical area.
Innovation Solution
A baffle design featuring a leading edge portion formed through additive manufacturing and a trailing edge portion made of sheet metal, both with cooling holes, bonded at a joint with a step, to enhance cooling air distribution and efficiency across the airfoil vane.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional manufacturing methods are used for baffles, then manufacturing simplicity is maintained, but cooling holes cannot be precisely placed near the trailing edge resulting in reduced cooling efficiency
Solution Approach 1:
The baffle is divided into two separate portions: a leading edge portion manufactured by additive manufacturing with precise cooling hole placement, and a trailing edge portion made from sheet metal. These portions are joined together to form the complete baffle, allowing each section to be optimized for its specific manufacturing requirements and functional needs.
Solution Approach 2:
The baffle combines two different material types: sintered metal from additive manufacturing for the leading edge portion and sheet metal for the trailing edge portion. This composite construction allows the leading edge to achieve precise cooling hole placement while the trailing edge maintains manufacturing simplicity and structural integrity.
2Manufacturing precision
If additive manufacturing is used for the entire baffle, then cooling hole precision is improved, but manufacturing cost and complexity increase
Solution Approach 1:
The baffle is segmented into two portions with different manufacturing methods: the leading edge portion requiring precise cooling holes is made by additive manufacturing, while the trailing edge portion is made from sheet metal through traditional fabrication methods, optimizing both precision and ease of manufacture for different sections.
Solution Approach 2:
Different manufacturing approaches are applied to different regions of the baffle based on local requirements: additive manufacturing is used only where precise cooling hole placement is critical (leading edge), while traditional sheet metal fabrication is used where simplicity and cost-effectiveness are prioritized (trailing edge).
3Reliability
If a single-piece baffle is used, then structural integrity is maintained, but cooling efficiency at the trailing edge is reduced
Solution Approach 1:
The baffle is divided into two portions that are joined together: the leading edge portion with precise cooling holes for optimal cooling efficiency, and the trailing edge portion providing structural support. The joining process maintains structural integrity while enabling the cooling holes to be precisely positioned for enhanced cooling performance.
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
The baffle design provides improved cooling efficiency at the trailing edge of airfoil vanes by allowing precise placement of cooling holes and maintaining structural integrity, addressing the inefficiencies of traditional manufacturing methods.
Implementation Method 1
A leading edge portion and a trailing edge portion are bonded at a bonded joint
Data Source
AI summary
An airfoil vane includes an airfoil section which includes an outer wall that defines an internal cavity. A baffle is situated in the internal cavity. The baffle includes a leading edge portion and a trailing edge portion which is bonded to the leading edge portion at a joint. The leading edge portion and the trailing edge portion define an internal cavity therewithin. Both the leading edge portion and the trailing edge portion include a plurality of cooling holes which are configured to provide cooling air to the airfoil outer wall. The trailing edge portion is formed of sheet metal and the leading edge portion is formed of non-sheet-metal. A method of making a baffle for a vane arc segment and a method of assembling a ceramic matrix composite airfoil vane are also disclosed.