Ceramic Airfoil Vane Support With Selective Thermal Barrier Coating
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Solution Overview
Problem
Implementing ceramic matrix composite (CMC) materials in airfoils of gas turbine engines faces challenges due to unique issues related to mechanical support and thermal protection, particularly in high-temperature environments, where the support structures made of metallic materials are susceptible to excessive heating and oxidation.
Innovation Solution
A thermal barrier coating (TBC) is applied to the metallic support structures, such as spar pieces, to enhance their heat resistance and oxidation resistance, while ensuring the sealing surfaces remain free of the coating to maintain effective sealing, thereby reducing cooling requirements and minimizing the risk of damage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If a thermal barrier coating is applied to the metallic support structure, then the heat resistance and oxidation resistance are improved, but the sealing surface performance deteriorates due to coating deposition
Solution Approach 1:
The patent applies thermal barrier coating selectively to specific regions of the support structure while leaving the sealing surface uncovered. This local differentiation allows the coated regions to provide thermal protection where needed, while the uncoated sealing surface maintains its sealing functionality without coating interference.
Solution Approach 2:
The support structure is divided into distinct functional zones: a sealing surface region that remains uncoated for optimal sealing contact, and a non-sealing region that receives the thermal barrier coating for heat and oxidation protection. This segmentation resolves the conflict between coating benefits and sealing requirements.
2Temperature
If cooling air is increased to protect metallic support structures from excessive heating, then the temperature control is improved, but the energy consumption increases
Solution Approach 1:
The thermal barrier coating acts as an intermediary layer between the metallic support structure and the high-temperature environment. This coating reduces the thermal load on the metal, thereby reducing the amount of cooling air needed to maintain safe operating temperatures and lowering overall energy consumption.
Solution Approach 2:
The thermal barrier coating serves as a protective sacrificial layer that absorbs thermal stress and oxidation damage, protecting the more valuable metallic support structure. This allows the system to operate with reduced cooling requirements while the coating provides its protective function.
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
The TBC improves the ability of support structures to withstand high temperatures, reduces cooling air requirements, and enhances the overall cooling efficiency of the engine by preventing excessive heating and oxidation of metallic components.
Implementation Method 1
A thermal barrier coating (TBC) is applied to the metallic support structures, such as spar pieces, to enhance their heat resistance
Implementation Method 2
A thermal barrier coating (TBC) is applied to the metallic support structures, such as spar pieces, to enhance their heat resistance and oxidation resistance
Implementation Method 3
A thermal barrier coating (TBC) is applied to the metallic support structures, such as spar pieces, to enhance their heat resistance and oxidation resistance
Data Source
Figure 1
Figure 2A~2C
Figure 3A~3B
AI summary
An airfoil vane assembly (100) according to an exemplary embodiment of this disclosure, among other possible things includes a vane piece (102) having a first vane platform (106), a second vane platform (108), and a hollow airfoil section (110) joining the first vane platform (106) and the second vane platform (108), a spar piece (104) having a spar platform (114) and a spar (116) extending from the spar platform (114) into the hollow airfoil section (110), and at least one seal (120) arranged at a sealing surface (122) of the spar platform (114) and sealing between the spar platform (114) and the first vane platform (106). The airfoil vane assembly (100) also includes a thermal barrier coating (124) disposed on the spar piece (104). The sealing surface (122) is free from the thermal barrier coating (124). A gas turbine engine and a method of making a spar piece (104) for an airfoil vane assembly (100) are also disclosed.