Ceramic Matrix Composite Airfoil Trailing Edge Cooling
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Solution Overview
Problem
Existing gas turbine engine cooling features, such as multiple rows of cooling holes, increase component thickness and weight, and are inefficient in reducing material failures due to elevated combustion temperatures, while also being costly and time-consuming to manufacture.
Innovation Solution
The design incorporates a ceramic matrix composite airfoil with a trailing edge cooling system that includes a plenum and cooling passages proximate the suction side, minimizing thickness and manufacturing time, and utilizing a filler pack between plenum and airfoil plies to direct cooling fluid efficiently.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If multiple rows of cooling holes are used to achieve film cooling, then cooling effectiveness is improved, but component thickness and weight increase
Solution Approach 1:
The cooling system is segmented into multiple functional zones: a plenum chamber for fluid distribution, multiple cooling passages at different locations (including proximate the suction side), and cooling holes at the trailing edge. This segmentation allows efficient cooling with reduced overall component thickness compared to traditional multi-row cooling hole configurations.
Solution Approach 2:
The invention transitions from a traditional multi-row cooling hole approach (increasing thickness in the spanwise direction) to a multi-passages-and-holes configuration that distributes cooling functionality across different spatial dimensions, including passages proximate the suction side and trailing edge, thereby achieving effective cooling without proportionally increasing component thickness and weight.
2Temperature
If multiple rows of cooling holes are used to achieve film cooling, then cooling effectiveness is improved, but manufacturing complexity and time increase
Solution Approach 1:
The manufacturing process is segmented into distinct stages: forming the plenum chamber, creating cooling passages, and adding cooling holes. This segmentation allows each feature to be optimized and manufactured independently, reducing overall manufacturing complexity and time compared to creating multiple rows of precisely aligned cooling holes through the entire component thickness.
3Quantity of substance
If traditional cooling hole configurations are used, then cooling fluid flow is maintained, but component thickness increases to accommodate tolerances
Solution Approach 1:
The invention redistributes cooling functionality from a thickness-intensive multi-row hole configuration to a multi-dimensional arrangement including passages proximate the suction side and trailing edge with cooling holes. This dimensional redistribution maintains cooling fluid flow while reducing the required component thickness to accommodate manufacturing tolerances.
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 solution reduces the thickness and weight of the airfoil, enhances cooling efficiency, and decreases manufacturing complexity and costs, while providing effective heat management for gas turbine engine components.
Implementation Method 1
a cooling passage defined within the trailing edge portion for directing a cooling fluid from the plenum to the outer surface of the airfoil
Data Source
AI summary
Airfoils for gas turbine engines are provided. In one embodiment, an airfoil formed from a ceramic matrix composite material includes opposite pressure and suction sides extending radially along a span and defining an outer surface of the airfoil. The airfoil also includes opposite leading and trailing edges extending radially along the span. The pressure and suction sides extend axially between the leading and trailing edges. The leading edge defines a forward end of the airfoil, and the trailing edge defining an aft end of the airfoil. Further, the airfoil includes a trailing edge portion defined adjacent the trailing edge at the aft end of the airfoil; a plenum defined within the airfoil forward of the trailing edge portion; and a cooling passage defined within the trailing edge portion proximate the suction side. Methods for forming airfoils for gas turbine engines also are provided.