Ceramic Matrix Composite Cooling Channels for Thermal Gradient Control
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Solution Overview
Problem
CMC gas turbine components face issues with crack formation, coating spallation, and recession due to extreme thermal gradients and high temperatures, limiting their service life and cooling efficiency.
Innovation Solution
A ceramic matrix composite component with integrated elongate functional features, such as cooling channels and insulating channels, formed within the plies to enhance cooling and structural integrity, using methods like melt infiltration and sacrificial fibers to create aligned cooling networks without weakening the structure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If cooling channels are added to CMC components, then cooling efficiency is improved, but structural integrity deteriorates
Solution Approach 1:
The component is divided into multiple plies (layers) of CMC material, with cooling channels formed within specific plies. This segmentation allows cooling functionality to be integrated without compromising the overall structural integrity, as each ply maintains its load-bearing capability while providing cooling pathways.
Solution Approach 2:
Cooling channels are strategically positioned in specific plies based on thermal gradient analysis. Not all plies require cooling channels, so the structure maintains optimal strength in critical load-bearing areas while providing enhanced cooling where thermal management is most needed.
2Strength
If multiple plies are stacked to form densified body, then structural integrity is improved, but manufacturing complexity increases
Solution Approach 1:
Cooling channels are formed within plies before the stacking and densification process. This preliminary action allows the channels to be pre-configured in each ply, and then the plies are stacked and densified as a complete assembly, simplifying the overall manufacturing process by combining multiple operations into a single workflow.
3Temperature
If cooling channels are formed in CMC components, then thermal gradient management is improved, but crack formation increases
Solution Approach 1:
Cooling channels are positioned in plies that experience the highest thermal gradients, providing targeted thermal management where it is most needed. This localized approach prevents excessive thermal stress concentration that would lead to cracks, while maintaining structural integrity in areas with lower thermal loading.
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 solution provides improved cooling efficiency, reduced thermal stresses, and enhanced structural integrity, extending the service life of CMC components by managing thermal gradients and maintaining uniform temperature distribution.
Implementation Method 1
Each of the one or more elongate functional features includes an inlet in fluid communication with a flow of cooling fluid from a fluid source
Implementation Method 2
forming a CMC preform comprising a matrix precursor, a plurality of reinforcing fibers and a plurality of sacrificial fibers; removing the plurality of sacrificial fibers such that one or more elongate functional features are formed in the CMC preform
Implementation Method 3
applying a fluid infiltrant to the CMC preform thereby densifying the CMC preform
Data Source
AI summary
A ceramic matrix composite component and method of fabrication including a plurality of longitudinally extending ceramic matrix composite plies in a stacked configuration forming a densified body and one or more elongate functional features formed therein and in alignment with the plurality of longitudinally extending ceramic matrix composite plies. Each of the elongate functional features includes an inlet configured to be in fluid communication with a flow of cooling fluid from a fluid source. One or more bores cut through the plurality of ceramic matrix composite plies from at least one of the one or more elongate functional features to an outlet proximate to an outer surface of the ceramic matrix composite component. One or more film cooling throughholes cut through the ceramic matrix composite plies from an inner surface of the ceramic matrix composite component to an outlet proximate to the outer surface of the ceramic matrix composite component.