Turbomachine Blade Internal Flow Disruptive Elements
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Solution Overview
Problem
Conventional aircraft turbine engine blades with integrated heat exchanger functions face challenges in ensuring complete contact between fins and walls during manufacturing, leading to reduced mechanical resistance, effective heat transfer, and increased risk of leaks due to high fluid pressures, while modifications for improved heat exchange often compromise aerodynamic performance.
Innovation Solution
The blade is manufactured using additive manufacturing with irregularly spaced and angled disturbing elements connecting the intrados and extrados walls, forming a complex internal fluid passage that enhances heat exchange and mechanical strength, and is oriented during production to minimize support requirements and reduce manufacturing imperfections.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If fins are attached between the aerodynamic walls to increase heat exchange surface area, then heat exchange efficiency is improved, but contact between fins and walls is incomplete leading to reduced mechanical strength and increased leak risk
Solution Approach 1:
The patent merges the fin structure with the aerodynamic walls by manufacturing them as a single integrated component using additive manufacturing. This eliminates the attachment interface between fins and walls, ensuring complete contact and eliminating leak paths while maintaining enhanced heat exchange surface area. The integrated structure also improves mechanical strength by creating a unified load-bearing architecture.
2Temperature
If the blade profile is modified to increase heat exchange potential, then heat exchange efficiency is improved, but aerodynamic performance is compromised
Solution Approach 1:
The patent adds the heat exchange function in a different dimension by incorporating internal fins and flow passages within the blade structure, rather than modifying the external aerodynamic profile. This allows the heat exchange surface area to be increased through internal geometric complexity while preserving the external aerodynamic shape and its performance characteristics.
3Ease of manufacture
If standard assembly methods are used to manufacture complex-shaped blades, then manufacturing complexity is reduced, but contact at every point between vanes and walls is not guaranteed leading to leaks and reduced heat transfer
Solution Approach 1:
The patent combines multiple manufacturing operations into a single additive manufacturing process that creates the blade, fins, and flow passages as one integrated component. This eliminates assembly steps and ensures perfect contact throughout the structure since there are no separate parts to join, thereby achieving both manufacturing feasibility and precise contact.
4Temperature
If ACOC heat exchangers are used to cool lubricant, then heat dissipation capacity is sufficient, but they disturb the secondary flow path reducing overall turbomachine efficiency
Solution Approach 1:
The patent makes the outlet guide vane serve multiple functions simultaneously: it maintains its aerodynamic function for flow guidance while also incorporating internal heat exchange passages and fins to cool the lubricant. This integration eliminates the need for separate ACOC heat exchangers that would occupy space in the secondary flow path, thereby preserving turbomachine efficiency while providing adequate heat dissipation capacity.
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 configuration increases heat exchange efficiency and mechanical strength, while being compatible with additive manufacturing processes, reducing the impact of manufacturing direction on aerodynamic wall quality and minimizing leaks, thus improving overall turbomachine performance.
Implementation Method 1
a heat exchange function between the secondary airflow flowing along the aerodynamic profile of the vane and a hydraulic lubricating fluid circulating within it
Implementation Method 2
fluid circulating through lubrication chambers for the bearings supporting the drive shafts and/or the fan hub
Implementation Method 3
These fins effectively disrupt the flow through the hydraulic fluid flow duct
Implementation Method 4
the powder bed additive manufacturing process, which involves stacking parallel layers of material from a build platform
Implementation Method 5
the metal laser melting additive manufacturing technique
Data Source
Figure 1~3
Figure 4~6
Figure 7
AI summary
The invention relates to an aircraft turbomachine blade comprising an aerodynamic part manufactured in one piece by additive manufacturing, this aerodynamic part comprising a pressure-side wall (37), a suction-side wall (38) and an internal fluid passage (43), this internal fluid passage (43) being crossed by a plurality of disruptive elements (66) that each connect the pressure-side wall to the suction-side wall, being irregularly spaced apart according to varied parameters in a chosen and optimized range, the junction of said disruptive elements (66) with the pressure-side and suction-side walls not following a particular arrangement along the internal passage so as to form a disorderly arrangement.