Airfoil Panel Cooling Channels and Segmented Coating
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Solution Overview
Problem
Gas turbine engines face efficiency penalties due to the need for compressor bleed cooling, which compromises thermodynamic efficiency and mass flow through the turbine, as components cannot withstand stoichiometric ideal temperatures, requiring enhanced thermal resistance at the compressor exit and turbine inlet.
Innovation Solution
The airfoil design incorporates a core structure with attached panels that form a cooling passage system, featuring channels and notches for efficient coolant distribution, and a geometric segmented coating for thermal resistance, reducing the need for compressor bleed cooling by enhancing temperature resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If compressor bleed cooling is used to protect components from high temperatures, then thermal resistance is improved, but thermodynamic efficiency and mass flow through the turbine deteriorate
Solution Approach 1:
The patent changes the physical and chemical parameters of the coating materials to achieve higher temperature resistance. Specifically, it uses thermal barrier coatings with low thermal conductivity and high melting point, along with environmental barrier coatings that resist chemical degradation at elevated temperatures, allowing the airfoil to operate at higher temperatures without compressor bleed cooling
Solution Approach 2:
The patent employs composite coating structures combining multiple materials with complementary properties. The coating system includes thermal barrier coatings (e.g., ceramic materials) for heat insulation, environmental barrier coatings (e.g., oxidation-resistant materials) for chemical protection, and bond coats for adhesion, creating a multi-layer composite structure that provides comprehensive thermal and environmental protection
2Temperature
If compressor bleed cooling is used to protect components from high temperatures, then thermal resistance is improved, but mass flow through the turbine deteriorate
Solution Approach 1:
By changing the material parameters of the airfoil coatings to withstand higher temperatures, the patent eliminates the need to extract mass flow from the compressor for cooling purposes. The advanced coating materials maintain structural integrity and protect the airfoil at elevated temperatures, preserving the full mass flow through the turbine for power generation
3Productivity
If higher temperatures are used in the compressor exit and turbine inlet, then thermodynamic efficiency is improved, but component temperature resistance deteriorates
Solution Approach 1:
The patent uses composite coating systems that combine thermal barrier materials with high melting points, environmental barrier materials with oxidation resistance, and metallic bond coats for adhesion. This multi-material composite structure enables the airfoil to withstand the higher temperatures required for improved thermodynamic efficiency while protecting the underlying metal components from thermal and chemical damage
4Temperature
If geometric segmented coating is applied to enhance thermal resistance, then temperature resistance is improved, but device complexity increases
Solution Approach 1:
The patent divides the coating system into distinct functional segments or layers, including thermal barrier coating layers, environmental barrier coating layers, and bond coat layers. Each segment is optimized for its specific function, allowing the complex protective capability to be achieved through modular, functionally-separated layers that can be applied and maintained more effectively than a monolithic coating
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 design enhances thermal resistance and reduces the need for compressor bleed cooling, thereby improving engine efficiency by allowing higher temperatures and velocities of compressor bleed air without compromising pressure differential.
Implementation Method 1
Each of the channels has a first end that opens to the cooling passage and a second end that opens to the exterior gas path side at one of the side edges
Implementation Method 2
at least one of the first or second panels includes a geometric segmented coating section
Data Source
AI summary
An airfoil includes a core structure that defines a cooling passage and first and second panels that are attached with the core structure. Each of the first and second panels includes an exterior gas path side, an opposed interior side, and a side edge. The side edge has a bearing portion that defines a bearing surface. The bearing surface of the first panel abuts the bearing surface of the second panel at a bearing interface. There are channels in the bearing portion of the first panel. Each of the channels has a first end that opens to the cooling passage and a second end that opens to the exterior gas path side at one of the side edges. Each of the channels is defined on a side by the bearing surface of the second panel.