Bi-material Adaptive Cooling Pathways for Turbine Hot Spots
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Solution Overview
Problem
Gas turbine components face challenges in efficiently managing localized hot spots due to insufficient cooling, leading to stress, oxidation, and potential damage, while overcooling compromises engine output and efficiency.
Innovation Solution
A bi-material adaptive cooling pathway filled with materials of different melting points, where a lower temperature outer material releases to expose a higher temperature inner material, creating a cooling flow when a predetermined temperature is reached, providing targeted supplemental cooling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If overcooling is applied to compensate for localized hot spots, then component reliability is improved, but engine output and efficiency deteriorate
Solution Approach 1:
The patent implements localized cooling by placing cooling plugs only at specific hot spot locations rather than uniformly cooling the entire component. The cooling plugs are strategically positioned in cooling pathways at locations where hot spots are expected to occur, providing cooling only where needed rather than overcooling the entire component, thus maintaining engine efficiency while preventing localized overheating damage
Solution Approach 2:
The cooling plugs are pre-installed in the cooling pathways before the component operates. These plugs are made of materials with melting points below the hot spot temperatures, so they are prepared in advance to automatically melt and open the cooling pathways when the predetermined temperature is reached, eliminating the need for real-time control decisions and enabling immediate responsive cooling
2Productivity
If insufficient cooling is applied, then engine output and efficiency are maintained, but component reliability deteriorates due to stress and oxidation
Solution Approach 1:
The patent changes the physical state parameter of the cooling plug material from solid to liquid/melted state at a predetermined temperature. The cooling plug is made of material whose melting point is below the hot spot temperature but above normal operating temperature, so it remains solid during normal operation (maintaining engine efficiency) but automatically melts when hot spots occur (providing necessary cooling protection)
Solution Approach 2:
The cooling system is self-regulating through the automatic melting of cooling plugs. When hot spots occur, the cooling plugs automatically melt and open the cooling pathways, allowing cooling air to flow to the affected areas without requiring external control systems, sensors, or actuation mechanisms, thus maintaining reliability while minimizing impact on engine performance
3Reliability
If uniform cooling is applied across the component, then localized hot spots are prevented, but excessive cooling air is consumed
Solution Approach 1:
The patent applies cooling only at specific localized positions where hot spots are expected to occur, rather than uniformly cooling the entire component. By placing cooling plugs only at critical locations in the cooling pathways, the system provides targeted cooling where needed, preventing hot spots while consuming minimal cooling air
Solution Approach 2:
The patent uses a partial action approach by implementing cooling plugs only at specific critical locations rather than throughout the entire component. This selective placement of cooling plugs provides sufficient cooling protection at hot spot locations without the excessive cooling air consumption that would result from uniform cooling across the entire component surface
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 allows for adaptive, efficient cooling that minimizes supplemental cooling air usage, extends component lifetime, and maintains engine efficiency by providing cooling only where needed, reducing overheating risks and field variations.
Implementation Method 1
The cooling plug may include a lower temperature outer material and a higher temperature inner material. The cooling plug may release to provide a cooling medium therethrough when a localized predetermined temperature is reached.
Implementation Method 2
flowing a cooling medium through the adaptive cooling pathway to cool at least a localized portion of the outer surface
Data Source
AI summary
A turbine component for use in a hot gas path of a gas turbine engine. The turbine component may include an outer surface, an internal cooling circuit, an adaptive cooling pathway in communication with the internal cooling circuit and extending through the outer surface, and a cooling plug having two or more materials positioned within the adaptive cooling pathway.