CMC Turbine Component With 3D-Printed Inner Cooling Passages

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Solution Overview

Problem

Ceramic matrix composites (CMCs) used in high-temperature applications like gas turbine engines are expensive and challenging to cool effectively, necessitating improved components with enhanced cooling features.

Innovation Solution

Utilizing additive manufacturing to create additively printed inner portions within CMCs that define complex cooling channels and passages, allowing targeted cooling and increased heat transfer coefficients, thereby eliminating the need for film cooling and reducing performance penalties.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If fiber-reinforced CMC material is used to achieve high strength-to-weight ratio and thermal resistance, then structural performance is improved, but manufacturing cost increases and cooling difficulty increases

Engineering Contradiction:

Improvestrength-to-weight ratioVSAvoidmanufacturing cost

Core Design Contradiction:

StrengthVSEase of manufacture

Solution Approach 1:

The component is divided into two distinct portions: an outer portion made of fiber-reinforced CMC material for structural strength, and an inner portion made of monolithic ceramic material for cost-effective cooling integration. This segmentation allows each portion to be optimized for its specific function while reducing overall manufacturing complexity and cost.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The invention uses a composite structure combining two different ceramic materials - fiber-reinforced CMC for the outer structural portion and monolithic ceramic for the inner cooling portion. This composite approach leverages the advantages of each material type to achieve both high strength-to-weight ratio and effective cooling at reduced cost.

Inventive Principle:

Principle #40Composite materials

2Temperature

If fiber-reinforced CMC material is used to achieve thermal resistance, then high-temperature strength is improved, but cooling difficulty increases

Engineering Contradiction:

Improvethermal resistanceVSAvoidcooling difficulty

Core Design Contradiction:

TemperatureVSEase of operation

Solution Approach 1:

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Different regions of the component are assigned different material properties: the outer portion uses fiber-reinforced CMC for thermal resistance and structural integrity, while the inner portion uses monolithic ceramic for ease of cooling channel integration. This local differentiation optimizes both thermal management and structural performance.

Inventive Principle:

Principle #3Local quality

3Temperature

If complex cooling channels are added to CMC components to improve cooling efficiency, then heat transfer is improved, but manufacturing complexity increases

Engineering Contradiction:

Improvecooling efficiencyVSAvoidmanufacturing complexity

Core Design Contradiction:

TemperatureVSDevice complexity

Solution Approach 1:

The component is divided into two distinct portions: an outer portion made of fiber-reinforced CMC material for structural strength, and an inner portion made of monolithic ceramic material for cost-effective cooling integration. This segmentation allows complex cooling channels to be manufactured in the inner portion using conventional techniques, reducing overall manufacturing complexity.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The inner monolithic ceramic portion acts as an intermediary that facilitates heat transfer from the outer CMC structure to the cooling fluid. This intermediary structure enables effective cooling without requiring complex channel geometries in the difficult-to-manufacture CMC portion.

Inventive Principle:

Principle #24Intermediary (Mediator)

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 additively printed inner portions enhance cooling efficiency and heat transfer in CMC components, improving their performance without increasing weight or cost, making them suitable for high-temperature applications.

Implementation Method 1

the additively printed inner portions enhance cooling efficiency and heat transfer in CMC components

Methodology Applied

Scientific EffectHeat transfer: Conduction (thermal)

Data Source

PatentUS12467369B2Composite component having an additively printed inner portion

Publication Date: 2025.11.11 GENERAL ELECTRIC CO

AI summary

A composite component for a gas turbine engine is provided, along with its methods of formation. The composite component includes: an additively printed inner portion defining at least one flowpath feature, and a ceramic matrix composite (CMC) outer portion formed on the additively printed inner portion such that the CMC outer portion substantially surrounds the additively printed inner portion. The additively printed inner portion includes SiC; and the CMC outer portion includes a fiber reinforced ceramic matrix (e.g., including SiC) and defines at least one cooling cavity fluidly coupled to the at least one flowpath feature of the additively printed inner portion.