Gas Turbine Blade Cooling Channel Segmentation

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Solution Overview

Problem

Existing methods for manufacturing gas turbine blades struggle to achieve a reduced wall thickness between the outer surface and the cooling channels, limiting heat transfer efficiency and increasing thermal stress.

Innovation Solution

A method involving forming a groove on the outer surface of the blade body and joining a cover to the blade body to create a cooling channel, allowing for a thinner wall thickness and improved heat transfer.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Temperature

If the wall thickness between the outer surface and cooling channel is reduced to improve heat transfer, then heat transfer efficiency is improved, but manufacturing reliability deteriorates due to casting tolerance limitations

Engineering Contradiction:

Improveheat transfer efficiencyVSAvoidmanufacturing reliability

Core Design Contradiction:

TemperatureVSReliability

Solution Approach 1:

The cooling channel is divided into two separate components: a groove formed in the blade body and a cover component that closes the groove. This segmentation allows the groove to be manufactured with standard casting tolerances while the cover thickness can be independently optimized for heat transfer, resolving the contradiction between manufacturability and thermal performance.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The invention changes the manufacturing approach from forming the complete cooling channel in a single casting process to a two-stage process where the cover is manufactured separately and joined to the blade body. This parameter change in the manufacturing process enables the wall thickness to be reduced to values that optimize heat transfer while remaining manufacturable through joining processes.

Inventive Principle:

Principle #35Parameter changes

2Temperature

If the wall thickness is reduced to improve cooling performance, then cooling efficiency is improved, but thermal stress increases

Engineering Contradiction:

Improvecooling efficiencyVSAvoidthermal stress

Core Design Contradiction:

TemperatureVSStress or pressure

Solution Approach 1:

By segmenting the cooling channel into a groove and a separate cover, the invention enables precise control of the wall thickness between the outer surface and cooling channel. This allows optimization of the thickness for heat transfer while the groove structure provides stress distribution, resolving the contradiction between cooling efficiency and thermal stress.

Inventive Principle:

Principle #1Segmentation

3Ease of manufacture

If a traditional casting process is used to manufacture the blade with cooling channels, then manufacturing simplicity is maintained, but minimum wall thickness is limited by casting tolerances

Engineering Contradiction:

Improvemanufacturing simplicityVSAvoidminimum wall thickness

Core Design Contradiction:

Ease of manufactureVSManufacturing precision

Solution Approach 1:

The cooling channel is segmented into a groove formed in the blade body and a separate cover component. This allows the groove to be manufactured using standard casting processes with conventional tolerances, while the cover can be manufactured separately with precise thickness control through other manufacturing methods, then joined to the blade body.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The groove acts as an intermediary structure that connects the blade body to the cover. By forming the groove in the blade body first, the invention creates a preparation structure that facilitates subsequent joining of the cover, enabling the manufacturing of thin-walled cooling channels that would be impossible with traditional single-step casting.

Inventive Principle:

Principle #24Intermediary (Mediator)

4Temperature

If the cover thickness is reduced to improve heat transfer, then heat transfer efficiency is improved, but manufacturing precision requirements increase

Engineering Contradiction:

Improveheat transfer efficiencyVSAvoidcover thickness precision

Core Design Contradiction:

TemperatureVSManufacturing precision

Solution Approach 1:

The invention changes the manufacturing paradigm from forming the complete cooling channel in one casting process to a two-stage process with separate manufacturing of the groove and cover. This parameter change in the manufacturing process allows the cover thickness to be optimized for heat transfer while using manufacturing processes appropriate for achieving the required precision.

Inventive Principle:

Principle #35Parameter changes

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 enhances heat transfer between the cooling fluid and the blade surface, reduces thermal stress, and increases the blade's lifetime while improving the efficiency of the gas turbine by reducing the mass flow rate of the cooling fluid.

Implementation Method 1

heat transfer between the cooling fluid flowing in the cooling channels

Methodology Applied

Scientific EffectHeat transfer: Conduction (thermal)

Data Source

PatentUS12234743B2Method for manufacturing a blade for a gas turbine, turbine blade and gas turbine

Publication Date: 2025.02.25 DOOSAN ENERBILITY CO LTD

AI summary

A method for manufacturing a blade for a gas turbine includes forming a blade body, forming a groove in an outer surface of the blade body, positioning a cover on the blade body such that it covers the groove and such that an outer surface of the cover forms a continuous surface with the outer surface of the blade body, and joining the cover to the blade body so that the cover and the groove define a cooling channel.