Blade Outer Air Seal Cooling Passage Geometry for Thermal Integrity

The patent applies local quality by varying the distance between the leading edge wall and cooling passage along the leading edge. Specifically, the distance is reduced at certain locations to enhance cooling efficiency where thermal loads are highest, while maintaining adequate distance at other locations to prevent casting defects. This localized optimization allows different regions of the leading edge to have different wall thickness characteristics suited to their specific thermal environments.

The patent employs curved or rounded geometries for the cooling passages, particularly at transitions and intersections, rather than sharp corners or abrupt changes. This curvature approach maintains smooth airflow through the passages, preventing flow separation and enhancing cooling efficiency. Simultaneously, the rounded geometries are more amenable to casting processes compared to sharp features, thus balancing manufacturing ease with thermal performance.

The patent utilizes parameter changes by varying the wall thickness and cooling passage distance as continuous variables along the leading edge geometry. Rather than using a uniform wall thickness, the design optimizes these parameters locally based on thermal load distribution, allowing minimum wall thickness to be used where cooling demands are highest while maintaining adequate thickness elsewhere. This parametric optimization reduces overall material usage and weight while preventing casting defects through localized thickness control.