Ceramic Cooling Panel Lamination for Turbine Heat Resistance
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Solution Overview
Problem
Current monolithic ceramic and ceramic matrix composite (CMC) systems in industrial gas turbine (IGT) components face limitations such as brittle behavior, low fracture toughness, limited fatigue resistance, creep resistance, high cost, and anisotropic mechanical properties, which restrict their application in high-temperature, mechanically loaded areas due to thermal and mechanical stress.
Innovation Solution
A modular structure assembly method using combined panel structures with specialized treatment, including the integration of isolation and cooling panels, and a CMC airfoil fixation on a metallic platform, employing a shrinking joint and mechanical interlocks to decouple thermal and mechanical loads, and using pins for cooling air holes without damaging the ceramic fibers, allowing for a single-step sintering process and minimizing post-processing steps.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If monolithic ceramic and CMC materials are used in high temperature loaded areas, then component T resistance and lifetime are improved, but mechanical strength and fracture toughness deteriorate due to brittle behavior
Solution Approach 1:
The patent employs ceramic matrix composite (CMC) materials that combine ceramic fibers with a matrix material to create a composite structure. This composite approach maintains the high temperature resistance of ceramics while improving mechanical strength and fracture toughness through the fibrous reinforcement structure, directly resolving the contradiction between temperature resistance and mechanical strength.
Solution Approach 2:
The patent divides the turbine component into multiple sections with different material compositions - using CMC materials in high temperature zones while maintaining metallic structures in mechanically loaded areas. This segmentation allows each zone to be optimized for its specific functional requirements, balancing thermal resistance and mechanical strength across the component.
2Use of energy by moving object
If CMC materials are used to reduce cooling requirements, then energy efficiency is improved, but creep resistance deteriorates under high temperature and mechanical load
Solution Approach 1:
The patent applies CMC materials selectively in specific zones where thermal protection is most needed, while maintaining metallic materials in areas subject to high mechanical loads and creep stress. This local differentiation optimizes energy efficiency by reducing cooling requirements in thermal zones without compromising creep resistance in mechanically critical areas.
Solution Approach 2:
The patent uses advanced CMC compositions with reinforced fiber structures and optimized matrix materials that simultaneously improve creep resistance and maintain thermal protection capabilities. The composite structure allows for enhanced high-temperature mechanical properties while preserving the low cooling requirement benefit.
3Strength
If multiple layer arrangements are used to achieve thicker material strengths, then mechanical strength is improved, but manufacturing complexity and risk of defects increase
Solution Approach 1:
The patent incorporates reinforcement fibers and structural features into the CMC material during the initial manufacturing process rather than adding them subsequently. This preliminary integration of strengthening elements simplifies the overall manufacturing process by eliminating multiple assembly steps while achieving the desired mechanical strength through the inherent composite structure.
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 approach enhances the mechanical, thermal, and creep resistance of IGT components, reduces cooling requirements, and extends component lifetime by mitigating thermal gradients and mechanical loads, while maintaining the integrity of the CMC layers and reducing production costs.
Implementation Method 1
cooling panels for cooling the CMC airfoil
Implementation Method 2
cooling air holes
Implementation Method 3
employing a shrinking joint
Implementation Method 4
allowing for a single-step sintering process
Data Source
Figure 1~4d
Figure 5a~8
Figure 9a~11
AI summary
A method of manufacturing a structured cooling panel comprises cutting of desized 2D ceramic into tissues; slurry infiltration in the tissues by at least one knife blade coating method; laminating the tissues in a multi-layer panel, with slurry impregnation after each layer, wherein the tissue has combined fibres and/or pre-build cooling holes; drying; de-moulding; sintering the multi-layer panel, wherein part of the combined fibres burns out during the sintering process leaving a negative architecture forming the cooling structure and/or the pre-build cooling holes define the cooling structure; finishing, using of i) post-machine, and/or ii) surface smoothening/rework, and/or iii) coating application, and/or other procedures.