Coated Turbine Cooling Apertures With Precise Meter-Diffuser Alignment
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Solution Overview
Problem
Existing methods for forming cooling apertures in turbine engine components, such as turbine blades and vanes, lack precision and efficiency, particularly in aligning the meter and diffuser sections of the cooling apertures, which can lead to misalignment and suboptimal cooling performance.
Innovation Solution
A method involving electrical discharge machining for forming the meter section, laser machining for the diffuser section, and the use of artificial intelligence or machine learning for precise alignment, combined with non-destructive microwave imaging to ensure accurate positioning of the diffuser section relative to the meter section, utilizing ceramic and metal coatings for enhanced thermal protection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional methods are used to form cooling apertures, then the manufacturing process is simpler, but the alignment precision between meter and diffuser sections deteriorates
Solution Approach 1:
The meter section is formed first as a reference feature before applying coatings and forming the diffuser section. This preliminary action establishes a precise alignment基准 that guides subsequent manufacturing steps, ensuring the diffuser section can be accurately positioned relative to the meter section despite process variations
Solution Approach 2:
Non-destructive imaging techniques are used to detect the position of the meter section through the coatings, and this detected position is fed back to guide the formation of the diffuser section. This closed-loop feedback mechanism ensures precise alignment while maintaining coating integrity
2Manufacturing precision
If cooling apertures are formed before applying coatings, then the aperture formation is easier, but the alignment between meter and diffuser sections deteriorates due to coating thickness variations
Solution Approach 1:
Non-destructive imaging techniques serve as an intermediary method to detect the meter section position through the coating layers without removing or damaging the coatings. This intermediary approach allows alignment verification and adjustment while maintaining the integrity of the coating system
Solution Approach 2:
Conventional mechanical methods that would require removing coatings to access and measure the meter section are replaced with non-destructive imaging techniques. This substitution eliminates the need for destructive inspection and rework, maintaining both coating integrity and manufacturing precision
3Manufacturing precision
If multiple scanning and detection steps are performed, then the alignment precision improves, but the manufacturing time increases
Solution Approach 1:
The meter section is formed and detected early in the process as a reference feature, establishing the alignment基准 before the diffuser section is formed. This preliminary detection avoids the need for extensive re-detection and adjustment later in the process, reducing overall manufacturing time while maintaining precision
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 achieves precise alignment and efficient formation of cooling apertures, enhancing the cooling performance and thermal protection of turbine engine components by ensuring accurate alignment and consistent geometry of the meter and diffuser sections.
Implementation Method 1
The meter section may be formed using an electrical discharge machining process
Implementation Method 2
The diffuser section may be formed using a laser machining process
Implementation Method 3
The imaging system may be configured as or otherwise include a microwave imaging system
Data Source
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AI summary
A manufacturing method (800) is provided. During this method (800), a preform component (60) is provided for a turbine engine (20). The preform component (60) includes a substrate (74'). A meter section (102) of a cooling aperture (64) is formed in the substrate (74'). An internal coating (138') is applied onto a surface of the meter section (102). An external coating (78') is applied over the substrate (74'). A diffuser section (104) of the cooling aperture (64) is formed in the external coating (78') and the substrate (74') to provide the cooling aperture (64).