Combustor Panel Gradient Transition Region Mitigates Thermal Fatigue

Solution Overview

Problem

Metal combustor panels in gas turbine engines are prone to thermal mechanical fatigue, leading to cracking and potential collisions with turbine engine structures due to high temperatures, which reduces their operational life.

Innovation Solution

A combustor thermal shield is developed, comprising a ceramic combustor panel with a transition region having a gradient material composition that transitions to a metal attachment stud and standoff pin, providing enhanced thermal protection and structural integrity through additive material deposition processes.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If metal combustor panels are used to provide strong fasteners and structural support, then structural strength is improved, but thermal mechanical fatigue resistance deteriorates leading to cracking

Engineering Contradiction:

Improvestructural strengthVSAvoidthermal mechanical fatigue resistance

Core Design Contradiction:

StrengthVSReliability

Solution Approach 1:

The combustor panel employs a composite structure combining ceramic material for the panel body with metal attachment studs. The ceramic provides thermal resistance while the metal studs provide mechanical strength for fastening. This composite approach resolves the contradiction by allowing each material to perform its optimal function - ceramic for thermal protection and metal for structural integrity.

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

Different regions of the combustor panel have different material compositions optimized for their specific functions. The panel body uses ceramic material for thermal resistance, while the attachment studs use metal for mechanical strength. This local differentiation of material properties allows the structure to simultaneously achieve both thermal fatigue resistance and structural strength.

Inventive Principle:

Principle #3Local quality

2Temperature

If ceramic material is used for combustor panels to resist high temperatures, then thermal resistance is improved, but mechanical strength and fastener retention deteriorate

Engineering Contradiction:

Improvethermal resistanceVSAvoidmechanical strength

Core Design Contradiction:

TemperatureVSStrength

Solution Approach 1:

The combustor panel employs a composite structure combining ceramic material for the panel body with metal attachment studs. The ceramic provides thermal resistance while the metal studs provide mechanical strength for fastening. This composite approach resolves the contradiction by allowing each material to perform its optimal function - ceramic for thermal protection and metal for structural integrity.

Inventive Principle:

Principle #40Composite materials

3Strength

If metal combustor panels are used to ensure structural integrity, then mechanical strength is improved, but operational life deteriorates due to thermal mechanical fatigue cracking

Engineering Contradiction:

Improvemechanical strengthVSAvoidoperational life

Core Design Contradiction:

StrengthVSDuration of action of stationary object

Solution Approach 1:

The combustor panel employs a composite structure combining ceramic material for the panel body with metal attachment studs. The ceramic provides thermal resistance while the metal studs provide mechanical strength for fastening. This composite approach resolves the contradiction by allowing each material to perform its optimal function - ceramic for thermal protection and metal for structural integrity.

Inventive Principle:

Principle #40Composite materials

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 combustor thermal shield effectively mitigates thermal mechanical fatigue, preventing panel cracking and ensuring the structural integrity of the combustor, thereby extending the operational life of gas turbine engine components.

Implementation Method 1

A method of forming a combustor thermal shield by an additive material deposition process is disclosed

Methodology Applied

Scientific EffectAdditive material deposition: Deposition (physical)

Data Source

PatentUS10451280B2Combustor panel having material transition region

Publication Date: 2019.10.22 RTX CORP

AI summary

A combustor thermal shield is provided. The combustor thermal shield may have a combustor panel that may protect a surface of a combustor from heat and/or flame. The combustor thermal shield may be mounted to the combustor by an attachment stud formed as a unitary body with the combustor panel. The combustor panel and the attachment stud may be made of different materials. A transition region may be disposed between the attachment stud and the combustor thermal shield and formed as a unitary body with the combustor panel and the attachment stud. The transition region may be made of a mixture of the different materials. The mixture may vary according to a gradient as a function of proximity to the combustor panel and the attachment stud.