Cold-Sprayed Annular Flow Control Duct With Reinforcing Rib Structure
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing flow control ducts in gas turbine engines face challenges in managing high mechanical and thermal loads while maintaining a lightweight construction.
Innovation Solution
The use of cold spray manufacturing techniques to create a closed loop annular component with a reinforcing structure, featuring a rib structure and specific spacing and thickness, which enhances stiffness and resistance to thermal loads.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If heavy construction is used to manage high mechanical and thermal loads, then strength and reliability are improved, but weight increases
Solution Approach 1:
The patent applies composite materials by combining a base metal material with a ceramic coating layer. The metal substrate provides mechanical strength and ductility, while the ceramic coating adds thermal resistance and hardness. This composite structure enables the component to withstand high mechanical and thermal loads simultaneously without requiring excessive weight, directly resolving the contradiction between strength and weight.
Solution Approach 2:
The patent implements local quality by applying the ceramic coating selectively to specific surfaces of the metal substrate that are exposed to thermal and mechanical loads. The coating thickness and material composition can be varied locally based on the specific operational requirements of different regions, providing enhanced protection where needed while minimizing unnecessary material usage and weight.
2Object-affected harmful factors
If thick construction is used to resist thermal loads, then thermal resistance is improved, but weight and complexity increase
Solution Approach 1:
The ceramic coating layer serves as a thermal barrier that provides excellent thermal resistance with minimal thickness. Ceramics have inherently low thermal conductivity, allowing the coating to protect the metal substrate from thermal loads without requiring thick construction. This resolves the contradiction by providing high thermal resistance while maintaining lightweight characteristics.
Solution Approach 2:
The patent changes the material parameter from pure metal to a metal-ceramic composite system. This parameter change enables the component to achieve superior thermal resistance properties without proportionally increasing weight, as the ceramic layer provides disproportionate thermal protection relative to its thin thickness.
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 results in a resilient and lightweight flow control duct configuration that effectively manages high mechanical and thermal loads, reducing weight and improving engine performance.
Implementation Method 1
spraying, with a nozzle, a first particulate of a first material towards a substrate; spraying, with the nozzle, a second particulate of a second material towards the substrate; depositing the first particulate on the substrate to form a first annular layer; and selectively depositing the second particulate on the first annular layer to form a reinforcing structure
Data Source
AI summary
A component for a turbine engine may be formed by spraying particulate with a nozzle toward a substrate. The particulate may be deposited to form one or more annular layers and a reinforcing structure. The component may be a closed loop annular component having a reinforcing structure of specific dimensions enabled by the methods described.