Airfoil Cooling Passage Flow Testing via Internal Plug Isolation
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Solution Overview
Problem
Testing flow in airfoil cooling passage networks is challenging due to the difficulty in isolating individual networks for testing without blocking adjacent outlets, which is tedious and requires precise application of blocking devices on curved surfaces.
Innovation Solution
The method involves applying plugs through an opening in the airfoil platform to block flow into the inlet orifices of all but one cooling passage network, allowing a test flow to be applied through the open inlet orifices of the isolated network, using adhesive tapes, elastomer boots, wax, or combinations thereof, and removing them using solvents or thermal volatilization for reuse.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If blocking devices are applied to curved surfaces to isolate cooling passage networks, then flow isolation is achieved, but the process becomes tedious and requires precise application
Solution Approach 1:
Instead of blocking the outlets on the curved outer surface of the airfoil, the patent blocks the inlet orifices from the internal core cavity side. This inversion of the blocking approach allows plugs to be applied to flat, accessible surfaces rather than curved surfaces, significantly easing the application process while maintaining effective flow isolation of the cooling passage networks
Solution Approach 2:
The patent introduces an intermediary structure (the internal core cavity) that provides access to the inlet orifices of the cooling passage networks. By using this intermediary space, the blocking operation can be performed from a convenient location rather than attempting to apply blocks to the difficult-to-reach curved outer surfaces
2Reliability
If blocking devices are applied to curved surfaces to isolate cooling passage networks, then flow isolation is achieved, but the process is time-consuming
Solution Approach 1:
By inverting the blocking approach to work from the internal core cavity rather than the curved outer surface, the patent enables much faster application of plugs. The flat, accessible surfaces inside the core cavity allow for rapid placement and removal of blocking devices, significantly reducing the time required for testing each cooling passage network while maintaining reliable flow isolation
3Reliability
If blocking devices are applied to curved surfaces, then adjacent outlets can be blocked, but precise application is required
Solution Approach 1:
The patent inverts the blocking approach by working from the internal core cavity where flat, accessible surfaces provide large targets for plug application. This eliminates the need for precise placement on curved surfaces, as the plugs can be easily applied to the flat inlet orifices viewed from the core cavity side, maintaining reliable flow isolation without requiring high manufacturing precision
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 allows for efficient and precise testing of each cooling passage network by isolating them for flow testing without obstructing adjacent outlets, facilitating rapid and accurate assessment of network functionality.
Implementation Method 1
The plugs are adhesive tapes
Implementation Method 2
removing the adhesive tapes using a solvent to dissolve the adhesive tapes
Implementation Method 3
removing the wax by thermal volatilization of the wax
Data Source
AI summary
A method of testing flow in an airfoil includes isolating a first cooling passage network of the airfoil by applying plugs to internal inlet orifices of the other ones of the cooling passage networks in the airfoil. The plugs block flow from an internal core cavity of the airfoil into the other ones of the cooling passage networks. The inlet orifices of the first cooling passage network are left open. A test flow is then applied to the internal core cavity and flows through the inlet orifices of the first cooling passage network.