Ceramic Matrix Composite Shroud with Integral Cooling Passages

Solution Overview

Problem

Gas turbine engine shrouds experience high temperatures and temperature gradients, leading to stress and durability issues, particularly in ceramic matrix composite materials, where forming suitable cooling passages is challenging due to the desired positioning of these passages.

Innovation Solution

A shroud design with a cooling passage extending circumferentially through the shroud body, formed using ceramic matrix composite materials, which includes a method of forming turbine components by providing ceramic matrix composite plies around a core, curing them to form a filler component, and assembling with a ply component to create a shroud with integral flanges and cooling passages.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If drilling is used to form cooling passages in ceramic matrix composite shrouds, then cooling passages can be formed, but the shroud structure is compromised and positioning precision is reduced

Engineering Contradiction:

Improvecooling passage formationVSAvoidcooling passage positioning

Core Design Contradiction:

Ease of manufactureVSManufacturing precision

Solution Approach 1:

The cooling passages are formed during the manufacturing process itself rather than as a subsequent step. The shroud is formed with integral cooling passages built into the structure during formation, eliminating the need for post-manufacturing drilling or modification that would compromise structural integrity and positioning precision.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The traditional mechanical drilling process is replaced with a formation process that creates cooling passages as an integral part of the shroud structure. This substitution eliminates the need for separate drilling operations that would compromise both structural integrity and positioning precision.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Temperature

If shrouds are formed from ceramic matrix composite materials, then high temperature resistance is improved, but forming suitable cooling passages becomes difficult and positioning becomes impossible

Engineering Contradiction:

Improvetemperature resistanceVSAvoidcooling passage formation

Core Design Contradiction:

TemperatureVSEase of manufacture

Solution Approach 1:

The cooling passages are formed during the manufacturing process itself rather than as a subsequent step. The shroud is formed with integral cooling passages built into the structure during formation, eliminating the need for post-manufacturing drilling or modification that would compromise structural integrity and positioning precision.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The shroud is formed from ceramic matrix composite materials that are specifically suited for withstanding high temperatures while allowing for the formation of cooling passages during the manufacturing process. The composite material structure enables both high temperature resistance and integrated cooling passage formation.

Inventive Principle:

Principle #40Composite materials

3Reliability

If cooling passages are added to reduce thermal gradients, then durability is improved, but device complexity increases

Engineering Contradiction:

Improveshroud durabilityVSAvoidshroud structure

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The cooling passages are merged with the shroud structure itself, forming an integrated design where the cooling passages are not separate additions but are built into the shroud as a unified structure. This merging approach reduces overall device complexity compared to adding separate cooling systems.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The cooling passages are formed during the manufacturing process itself rather than as a subsequent step. The shroud is formed with integral cooling passages built into the structure during formation, eliminating the need for post-manufacturing drilling or modification that would compromise structural integrity and positioning precision.

Inventive Principle:

Principle #10Preliminary action

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 design reduces thermal gradients within the shroud, enhancing durability by facilitating improved cooling and stress reduction, while allowing for effective formation of cooling passages without the need for drilling.

Implementation Method 1

the cooling passage extending generally circumferentially through the shroud

Methodology Applied

Scientific EffectThermal conduction: Conduction (thermal)

Implementation Method 2

curing the one or more ceramic matrix composite plies to form a filler component

Methodology Applied

Scientific EffectCuring:

Data Source

PatentUS10689998B2Shrouds and methods for forming turbine components

Publication Date: 2020.06.23 GENERAL ELECTRIC CO

AI summary

Shrouds and methods for forming turbine components are provided. A shroud includes a shroud body which includes a forward surface, a rear surface axially spaced from the forward surface, an inner surface extending between the forward surface and the rear surface, and an outer surface extending between the forward surface and the rear surface and radially spaced from the inner surface. The shroud further includes a forward flange extending from the outer surface of the shroud body, and a rear flange extending from the outer surface of the shroud body, the rear flange axially spaced from the forward flange. The shroud further includes a cooling passage defined in the shroud, the cooling passage extending generally circumferentially through the shroud.