Ceramic Insert Blade Outer Air Seal for Gas Turbine
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Solution Overview
Problem
Conventional blade outer air seal systems in gas turbine engines are inefficient due to the need for cooling, which reduces engine thrust and increases costs, and they are prone to damage from high pressures and hot gas flows.
Innovation Solution
A blade outer air seal system featuring a ceramic insert member with a dovetail attachment section that can be easily replaced, reducing the need for complex cooling passages and utilizing a bias member and seals to enhance sealing and minimize leakage, with the ceramic material providing high temperature resistance and wear resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If cooling passages are formed in the blade outer air seal to maintain seal temperature, then the seal temperature is controlled, but engine thrust is reduced and manufacturing cost increases
Solution Approach 1:
The patent extracts the cooling function from the blade outer air seal by removing the cooling passages entirely. Instead of cooling the seal internally, the design uses a ceramic insert member that is inherently resistant to high temperatures, eliminating the need for cooling air extraction and associated performance penalties.
Solution Approach 2:
The patent changes the material parameter of the seal from conventional metal alloy to ceramic material. This parameter change fundamentally alters the temperature resistance characteristics, allowing the seal to operate at high temperatures without requiring active cooling systems.
2Temperature
If cooling passages are formed in the blade outer air seal to maintain seal temperature, then the seal temperature is controlled, but manufacturing cost increases
Solution Approach 1:
The patent removes the complex cooling passage structure from the seal design, significantly simplifying manufacturing. The ceramic insert member is designed as a simple replacement component that can be installed without requiring intricate cooling system fabrication.
Solution Approach 2:
By changing the material to ceramic, the patent eliminates the need for cooling passages, reducing manufacturing complexity and cost. The ceramic material's inherent heat resistance removes the requirement for expensive cooling system components and assembly.
3Strength
If conventional metal alloy is used for the blade outer air seal to withstand high pressures, then the seal strength is sufficient, but the seal is prone to damage from hot gas flow
Solution Approach 1:
The patent uses a ceramic insert member within the metal seal structure, creating a composite system. The ceramic provides exceptional resistance to hot gas flow and thermal damage, while the metal housing maintains structural strength and pressure containment capabilities.
Solution Approach 2:
The patent changes the material composition from pure metal alloy to ceramic-composite structure. This parameter change fundamentally improves durability against hot gas exposure while maintaining the necessary mechanical strength through the hybrid material system.
4Reliability
If a replaceable ceramic insert member is used in the blade outer air seal, then the seal durability is enhanced, but the device complexity increases
Solution Approach 1:
The patent divides the seal into two functional segments: a reusable metal housing and a replaceable ceramic insert member. This segmentation allows the ceramic component to be replaced independently when worn, extending the overall seal life without requiring replacement of the entire seal assembly.
Solution Approach 2:
The ceramic insert member is designed as a consumable component that can be easily replaced. When the ceramic wears or damages, only this specific insert member needs replacement, not the entire seal housing, reducing waste and lowering long-term maintenance costs.
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 simplifies the design, reduces the need for cooling, and enhances the durability and efficiency of the blade outer air seal system by minimizing the interaction with hot gas flows and reducing the complexity of cooling systems, thereby improving engine performance and reducing costs.
Implementation Method 1
the ceramic material providing high temperature resistance and wear resistance
Implementation Method 2
the ceramic material providing high temperature resistance and wear resistance
Implementation Method 3
a bias member and seals to enhance sealing and minimize leakage
Data Source
AI summary
A blade outer air seal system includes a body that extends between two circumferential sides, a leading edge and a trailing edge, and a radially inner side and a radially outer side. An attachment section associated with the body and includes at least one engagement surface that is transverse to the radially outer side.