Gas Turbine Blade Tip Cooling via Additive Overhang Grooves
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Gas turbine engines face inefficiencies due to high turbine inlet temperatures exceeding material melting points, requiring significant cooling that incurs cycle penalties, particularly at the high-temperature turbine blade tips where traditional cooling methods are inadequate.
Innovation Solution
A novel cooling configuration involving a recessed pocket with a teardrop-shaped design and additively manufactured overhang, combined with discrete holes for fluid communication, enhances cooling efficacy by creating a complex geometry that traditional methods cannot form, utilizing additive manufacturing techniques to deposit a second airfoil portion onto a cast first portion, forming a cooling groove and channel system.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If traditional cooling methods are used for turbine blade tips, then the blade tip temperature can be reduced, but the cooling efficacy is inadequate and cycle penalties are significant
Solution Approach 1:
The cooling system is segmented into multiple functional zones: a recessed pocket at the blade tip, cooling grooves on the pressure and suction sides, discrete cooling holes, and a continuous channel connecting these features. This segmentation allows each zone to perform a specific cooling function, improving overall cooling efficacy at the blade tip
Solution Approach 2:
The invention implements local cooling quality by concentrating cooling resources at the blade tip region through the recessed pocket and tip-rail structure. The cooling grooves are strategically positioned on the pressure and suction sides to provide localized cooling where heat flux is highest, rather than uniform cooling across the entire blade
2Power
If higher turbine inlet temperatures are used to improve engine efficiency, then engine performance is enhanced, but the temperatures exceed material melting points requiring significant cooling
Solution Approach 1:
The cooling system performs preliminary cooling action by extracting cooling air from the compressor and distributing it through the internal cooling passages and film cooling holes before the hot combustion gases reach the blade surfaces. This preemptive cooling allows the blade to withstand higher inlet temperatures without exceeding material limits
3Temperature
If dedicated cooling air is extracted from the compressor to cool gas path components, then component temperatures are controlled, but cycle penalties are significant
Solution Approach 1:
The invention concentrates cooling efforts locally at the blade tip region where heat flux is highest, rather than cooling the entire blade uniformly. The recessed pocket and tip-rail structure create a localized cooling zone that maximizes cooling effectiveness at the most critical area, potentially reducing the total amount of cooling air required
Solution Approach 2:
The cooling system segments the cooling air flow into different pathways: some air flows through internal cooling passages, while other air is directed through film cooling holes and the recessed pocket structure. This segmentation allows optimized cooling distribution that may improve thermal efficiency by targeting cooling only where most needed
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 provides increased engine efficiency through enhanced blade tip cooling, leveraging internal convection and optimized fluid distribution, effectively managing high temperatures and improving overall performance.
Implementation Method 1
a cooling groove (50) enclosed by an overhang (42) and an adjacent wall, the cooling groove providing a cooling fluid path
Implementation Method 2
enhanced cooling efficacy by creating a complex geometry that traditional methods cannot form, utilizing additive manufacturing techniques
Data Source
Figure 1A~1B
Figure 2A~2B
Figure 3A~4
AI summary
A gas turbine engine component includes a structure having a surface configured to be exposed to a hot working fluid. The surface includes a recessed pocket that is circumscribed by an overhang. At least one cooling groove is provided by the overhang.