Airfoil Assembly with Refractory Alloy Exterior Wall
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Solution Overview
Problem
Gas turbine engines face challenges in managing stress on airfoils under extreme temperatures, where high temperature-resistant materials are needed but often compromise on strength and toughness, and bleed air cooling reduces efficiency.
Innovation Solution
The use of airfoil assemblies with exterior walls made of refractory metal-based alloys or ceramic-based materials, combined with a support frame and spacers to manage stress, and impingement cooling features to reduce the need for bleed air cooling, while maintaining temperature resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If high temperature-resistant materials (refractory metal-based alloys, ceramic-based materials) are used for airfoil exterior walls, then temperature resistance is improved, but strength and toughness deteriorate
Solution Approach 1:
The airfoil assembly uses a composite structure combining high temperature-resistant materials (refractory metal-based alloys or ceramic-based materials) for the exterior wall with a support frame made of different material properties. This composite approach allows the exterior wall to withstand extreme temperatures while the support frame provides the necessary structural strength and toughness, resolving the contradiction between temperature resistance and mechanical strength.
2Temperature
If bleed air cooling is used to cool airfoils, then temperature control is improved, but engine efficiency deteriorates
Solution Approach 1:
The airfoil assembly is designed to withstand extreme temperatures through the use of high temperature-resistant materials for the exterior wall, eliminating the need for active cooling systems that consume bleed air. The structure serves itself by inherently resisting thermal damage, thereby maintaining engine efficiency while achieving effective temperature control.
3Strength
If a support frame is added to manage stress on airfoils, then structural strength is improved, but device complexity increases
Solution Approach 1:
The airfoil assembly is segmented into distinct functional components: an exterior wall made of high temperature-resistant material and a support frame made of different material. This segmentation allows each component to be optimized for its specific function (thermal resistance vs. structural support) while maintaining a relatively simple overall structure. The support frame protrudes through openings in the exterior wall, creating a modular assembly that is easier to manufacture and maintain.
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 solution effectively reduces stress on airfoils, enhances temperature resistance, and improves engine efficiency by minimizing the need for bleed air cooling, leading to significant fuel savings and increased power transfer efficiency.
Implementation Method 1
a portion of the support frame in the interior cavity includes impingement cooling features that are configured to direct cooling fluid in a direction toward an interior surface of the exterior wall
Data Source
AI summary
An airfoil assembly includes an airfoil that has an exterior wall that defines an interior cavity. The exterior wall extends between a leading end and a trailing end and an open inboard end and an open outboard end. The exterior wall is formed of a high temperature-resistant material selected from refractory metal-based alloys, ceramic-based material or combinations thereof. A support frame extends in the interior cavity and protrudes from the interior cavity through at least one of the open inboard end and the open outboard end.