Turbine Airfoil Impingement Insert Cooling
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Solution Overview
Problem
Gas turbine airfoils face inefficiencies in fluid cooling due to crossflow in the post-impingement cavity and non-optimized flow paths, leading to reduced cooling effectiveness and thermal stress under high operating temperatures and pressures.
Innovation Solution
An impingement insert with angled fins and cooling holes is integrated into the airfoil, enhancing fluid recirculation and heat transfer by increasing the cooling surface area and optimizing fluid flow, allowing for more uniform coolant distribution and reduced fluid usage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If conventional cooling manifolds with impingement holes are used, then cooling is provided to the airfoil, but crossflow in the post-impingement cavity inhibits cooling effectiveness
Solution Approach 1:
The cooling system is segmented into distinct functional zones: impingement holes for direct cooling, angled fins for flow direction control, and a post-impingement cavity for recirculation. This segmentation allows each component to address specific cooling challenges independently, eliminating crossflow issues while maintaining effective cooling.
Solution Approach 2:
The patent introduces angled fins that extend into the post-impingement cavity, adding a third dimension to the flow path control. These fins create vertical flow components that redirect coolant away from crossflow patterns, transforming the two-dimensional cavity flow into a three-dimensional recirculation pattern that enhances cooling effectiveness.
2Temperature
If cooling fluid flow is increased to overcome crossflow, then cooling effectiveness may improve, but fluid usage increases
Solution Approach 1:
The angled fins create a recirculation pattern where cooling fluid is redirected back toward the impingement zone, forming a feedback loop. This recirculation allows the same fluid to multiple passes over critical heat zones, increasing cooling effectiveness without proportionally increasing fluid consumption.
Solution Approach 2:
The cooling system combines multiple flow path elements (impingement holes, angled fins, cavity structures) into a composite cooling architecture. This composite structure optimizes fluid utilization by creating interconnected flow paths that maximize heat transfer efficiency per unit of coolant.
3Use of energy by moving object
If conventional impingement cooling is used, then cooling is provided, but non-optimized flow paths reduce cooling efficiency
Solution Approach 1:
The angled fins are strategically positioned at specific angles and locations within the post-impingement cavity to optimize local flow patterns. Each fin is designed with specific geometric properties tailored to redirect flow in critical cooling zones, creating locally optimized flow paths that enhance overall cooling efficiency.
Solution Approach 2:
The patent modifies flow path parameters by introducing fins with specific angles, heights, and spacing. These parameter changes transform the flow regime from crossflow-dominated to recirculation-dominated, optimizing the energy utilization of the cooling fluid without requiring fundamental system redesign.
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 configuration improves cooling efficiency, reduces thermal stress, and extends the service life of turbine components by increasing the heat transfer coefficient by up to 20% and achieving uniform temperature distribution.
Implementation Method 1
The fluid then exits the manifold through impingement holes into a post-impingement cavity
Implementation Method 2
crossflow in the post-impingement cavity, and non-optimized flow paths inhibit fluid cooling
Implementation Method 3
subsequently exits the post-impingement cavity through apertures in the exterior wall of the airfoil, forming a film layer of the fluid on the exterior of the airfoil
Implementation Method 4
forming a film layer of the fluid on the exterior of the airfoil
Data Source
Figure 1~2
Figure 3~5
Figure 6
AI summary
An airfoil (101) including a leading edge (104), a trailing edge (105), a pressure side (106), a suction side (107), and an internal impingement cavity (110). An impingement insert (120) is located within the impingement cavity (110). The impingement insert (120) includes at least one impingement cooling hole (125) spaced along a first face (127) of the impingement insert (120) and at least one impingement fin (130), having a base (132) and a tip (134) opposite the base (132), spaced along the first face (127) of the impingement insert (120). The at least one impingement fin (130) is spaced apart from the at least one impingement cooling hole (125).