Additively Manufactured Airfoil with Integral Impingement Baffle
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Solution Overview
Problem
Current gas turbine engine airfoils face challenges in adaptability and efficiency of cooling configurations, as traditional impingement baffle inserts are difficult to manufacture and install for specific cooling needs, leading to inefficiencies in engine performance and increased fuel consumption.
Innovation Solution
The integration of an integral impingement baffle within the airfoil through additive manufacturing, creating a monolithic structure with pre- and post-impingement chambers and cooling holes, allows for tailored cooling schemes and reduced part count, assembly complexity, and fuel consumption.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If traditional impingement baffle inserts are used for cooling, then cooling functionality is provided, but adaptability to specific cooling locations is poor and assembly complexity increases
Solution Approach 1:
The patent integrates the impingement baffle directly into the airfoil structure, merging two previously separate components (airfoil and baffle insert) into a single monolithic structure. This integration eliminates the need for separate assembly steps, reduces part count, and enables tailored cooling configurations at specific locations without increasing assembly complexity
Solution Approach 2:
The integrated baffle design allows for localized cooling configurations at specific airfoil locations. The baffle geometry can be customized to direct cooling fluid to precise areas where it is most needed, providing location-specific cooling adaptability while maintaining a unified structure
2Ease of manufacture
If traditional impingement baffle inserts are manufactured and installed, then cooling is provided, but manufacturing difficulty and installation complexity increase
Solution Approach 1:
By combining the airfoil and impingement baffle into a single integrated component, the patent eliminates the need to manufacture and install separate baffle inserts. The monolithic structure is manufactured as one piece, significantly simplifying the manufacturing process and reducing part count while maintaining all necessary cooling functionality
Solution Approach 2:
The integrated airfoil-baffle structure serves multiple functions simultaneously: it provides the aerodynamic airfoil function while also incorporating the impingement baffle cooling function. This multi-functionality eliminates the need for separate dedicated cooling components, simplifying both manufacturing and assembly
3Productivity
If cooling fluid is directed to specific locations, then engine performance improves, but cooling configuration complexity increases
Solution Approach 1:
The integrated baffle design enables localized cooling by directing cooling fluid to specific airfoil locations where it is most needed. The baffle geometry is customized to create targeted cooling zones, improving engine performance through precise thermal management without requiring complex multi-component cooling systems
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 approach enables improved engine performance by directing cooling fluid to specific locations, reducing fuel consumption and assembly complexity while maintaining manufacturing efficiency and cost-effectiveness.
Implementation Method 1
an impingement baffle insert may be received within the airfoil cavity such that the cooling fluid may pass through the baffle and impinge on inner surfaces of the airfoil to cool the airfoil
Implementation Method 2
The cooling fluid may then be expelled from the airfoil interior, e.g., as a film of cooling fluid to cool the airfoil exterior
Data Source
AI summary
Airfoils, additively manufactured airfoils, and methods of manufacturing airfoils are provided. For example, an airfoil comprises opposite pressure and suction sides that extend axially from a leading edge to a trailing edge and radially spaced apart inner and outer ends. The airfoil also comprises an outer wall defining the pressure and suction sides and leading and trailing edges. A rib extends within the airfoil from the pressure side to the suction side of the outer wall and radially from the inner to the outer end. The airfoil further comprises a first pre-impingement chamber surrounded by a first post-impingement chamber and a first dividing wall segment separating the first pre-impingement and first post-impingement chambers and having a plurality of cooling holes defined therein. The outer wall, rib, and first dividing wall segment are integrally formed as a single monolithic component.