CMC Gas Turbine Tile with Hollow Core for Thermal Protection
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Solution Overview
Problem
Current high-temperature ceramic tiles used in gas turbines face limitations due to poor mechanical properties, high cost, limited machinability, sensitivity to flaws, and difficulty in incorporating cooling channels and vibration dampers, which restrict operational windows and increase the risk of failure.
Innovation Solution
A low-cost, high-temperature resistant ceramic matrix composite (CMC) tile is developed using the filament winding method to create a 'hybrid' structure with a solid base, hollow middle, and solid top layers, incorporating integral voids, anchoring features, and porous ceramic layers for enhanced thermal protection and machinability, allowing for efficient cooling and vibration damping.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If monolithic ceramic tiles are used, then thermal protection is provided, but mechanical properties are poor and reliability is low
Solution Approach 1:
The patent uses ceramic matrix composite (CMC) material consisting of ceramic fibers embedded in a ceramic matrix, combining the thermal stability of monolithic ceramic with the enhanced mechanical strength and toughness of composite materials. The fiber-reinforced structure provides crack propagation resistance while maintaining thermal protection capabilities.
2Strength
If solid CMC tiles are used, then mechanical properties improve, but production cost increases due to fiber requirements
Solution Approach 1:
The patent incorporates a porous ceramic foam layer as the outer covering, which reduces the overall fiber content required in the tile structure. The foam structure provides thermal protection and mechanical integrity while using significantly less expensive fiber material compared to solid CMC tiles.
3Productivity
If complex cooling channels are incorporated, then cooling efficiency improves, but manufacturing difficulty increases
Solution Approach 1:
The cooling system is segmented into multiple channels distributed throughout the porous foam layer and CMC structure, allowing efficient heat removal without requiring a single complex cooling passage. The distributed network of cooling channels is easier to manufacture while maintaining high cooling efficiency.
4Ease of operation
If damping features are added, then vibration reduction improves, but machining capability is limited
Solution Approach 1:
The damping features are integrated into the tile structure during the manufacturing process rather than being added afterward. The porous foam layer and CMC structure are formed with inherent damping characteristics that reduce vibrations, eliminating the need for post-manufacturing machining or assembly of separate damping components.
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 CMC tiles offer superior mechanical properties, reduced production costs, improved reliability, and extended operational windows, enabling efficient thermal protection and vibration management while maintaining low thermal conductivity, thus enhancing the performance and lifespan of gas turbines.
Implementation Method 1
an outer covering layer (17) made of a porous ceramic material, attached to the upper solid CMC layer (8)
Implementation Method 2
CMC tiles can in fact provide a significant improvement in mechanical properties with respect to monolithic ceramic tiles
Data Source
Figure 1
Figure 2~9
Figure 4.1~4.9
AI summary
A tile (1), in particular a high-temperature resistant tile for lining internal surfaces of gas turbines, having a body (2) made of a CMC material consisting of ceramic fibers embedded in a ceramic matrix; the body (2) comprising a hollow CMC structure (6) between a lower solid CMC layer (7) and an upper solid CMC layer (8); wherein the lower solid CMC layer (7) and the upper solid CMC layer (8) are solid homogeneous layers, having no cavities or void spaces inside the CMC material; and the hollow CMC structure (6) comprises a cell pattern (9), extending between opposite faces (12, 13), facing each other and substantially parallel to each other, of the layers (7, 8), and consisting of a plurality of cells (10) defined by respective cavities and delimited by lateral walls (14) and arranged side-by-side on at least one cell layer (11).