Ceramic Matrix Composite Turbine Vane Heat Transfer Augmentation
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Solution Overview
Problem
Design and manufacture of high-temperature resistant vanes and blades for gas turbine engines using composite materials are challenging due to geometry and strength requirements, and existing solutions do not effectively enhance heat transfer for cooling purposes.
Innovation Solution
A method of forming ceramic matrix composite turbine vanes with heat transfer augmentation features, such as protrusions or flow separators, by chemical vapor infiltration and slurry impregnation, to increase heat transfer between the vane and cooling air, while maintaining a gap with metallic spar components to prevent conductive heat transfer.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If cooling air flow is increased to reduce material temperatures, then heat transfer is improved, but energy consumption and system complexity increase
Solution Approach 1:
The vane incorporates a porous structure with controlled porosity (30-70%) that enables effective heat transfer between cooling air and the ceramic matrix composite material. The porous geometry increases surface area for heat exchange while maintaining structural integrity, allowing efficient cooling without requiring excessive cooling air flow.
Solution Approach 2:
The vane features localized heat transfer augmentation features including protrusions, recesses, and varied porosity distributions in specific regions. These local modifications create zones of enhanced heat transfer where most needed, allowing targeted cooling optimization without uniformly increasing cooling air consumption across the entire vane structure.
2Temperature
If composite materials are used to withstand high temperatures, then temperature resistance is improved, but manufacturing complexity and cost increase
Solution Approach 1:
The manufacturing process uses a preform structure as a preliminary framework that guides subsequent infiltration steps. The preform is chemically vapor infiltrated and then impregnated with matrix material in sequential operations, allowing complex ceramic matrix composite structures to be built up systematically from simpler precursor components, thereby managing manufacturing complexity.
Solution Approach 2:
The invention employs ceramic matrix composite materials combining ceramic fibers with matrix material to achieve high-temperature resistance. The composite structure provides both thermal stability and mechanical strength, enabling the vane to withstand turbine operating temperatures while maintaining structural integrity through the synergistic properties of the composite system.
3Temperature
If heat transfer augmentation features are added to increase cooling efficiency, then heat transfer is improved, but manufacturing complexity increases
Solution Approach 1:
Heat transfer augmentation features such as protrusions and recesses are selectively placed in specific regions of the vane where heat transfer enhancement is most beneficial. The porosity and feature density vary locally to match thermal loading conditions, providing targeted cooling enhancement without uniformly complicating the entire vane geometry.
Solution Approach 2:
The porous structure itself serves as a heat transfer augmentation mechanism, with pore size, distribution, and connectivity optimized to enhance convective and conductive heat transfer. This porous approach provides effective heat transfer enhancement through material structure rather than adding separate geometric features, thereby limiting the increase in manufacturing complexity.
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 method effectively enhances heat transfer and cooling efficiency of the ceramic matrix composite vanes in gas turbine engines, reducing material temperatures without increasing cooling air flow, and maintains structural integrity by avoiding conductive heat transfer to metallic components.
Implementation Method 1
The fiber preform may be chemical vapor infiltrated to produce a porous preform with a plurality of protrusions in the passageway
Implementation Method 2
impregnating the porous preform with a slurry material and drying the slurry material to form a green body preform
Implementation Method 3
infiltrating the green body preform with a matrix material to form a ceramic matrix composite vane
Implementation Method 4
The heat transfer augmentation features may be configured to increase heat transfer between the ceramic matrix composite vane and cooling air supplied to the passageway
Data Source
AI summary
A turbine vane assembly adapted for use in a gas turbine engine includes a support and a turbine vane arranged around the support. The support is made of metallic materials. The turbine vane is made of ceramic matrix composite materials to insulate the metallic materials of the support.