Gas Turbine Combustor Shell Thermal Barrier Coating
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Solution Overview
Problem
Gas turbine combustor sections face distress due to elevated temperatures, leading to corrosion, cracking, and material liberation from direct hot gas exposure, radiation, and reduced airflow, which compromises the service life of the liner shells.
Innovation Solution
The application of thermal barrier coatings, comprising a metallic bond coat and a ceramic top coat, on both the liner and shell surfaces to protect against high-temperature environments, combined with impingement and effusion cooling techniques to manage heat and prevent distress.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If the combustor shell is exposed to hot combustor gases through direct contact, panel inflow, and/or radiation, then the combustor can operate at high temperatures for energy production, but the shell experiences elevated temperatures leading to corrosion, cracking, leakage and material liberation
Solution Approach 1:
A thermal barrier coating system comprising a metallic bond coat and a ceramic top coat is applied to the combustor shell to serve as an intermediary protective layer. This coating system isolates the shell material from direct exposure to hot combustor gases, panel inflow, and radiation, thereby preventing corrosion, cracking, leakage and material liberation while allowing the combustor to operate at high temperatures for energy production
Solution Approach 2:
The thermal barrier coating utilizes a composite material structure with a metallic bond coat (such as nickel-based alloy) providing adhesion and corrosion resistance, and a ceramic top coat providing thermal insulation and resistance to hot gas exposure. This composite coating system protects the combustor shell from high-temperature distress while maintaining structural integrity
2Reliability
If thermal barrier coatings are applied to protect the combustor shell, then the service life and structural integrity are extended, but the manufacturing process becomes more complex
Solution Approach 1:
The thermal barrier coating is applied to the combustor shell during the manufacturing process before the shell is installed in the engine. This preliminary action ensures proper coating adhesion and uniform coverage, and allows for quality control inspections to be performed before the coating is subjected to operational stresses, thereby extending service life while managing 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 thermal barrier coatings extend the service life of the combustor components by preventing cracking, leakage, and material liberation, while maintaining structural integrity and reducing environmental corrosion.
Implementation Method 1
Radiation is possible through dilution holes, igniter holes and other interfaces. The elevated temperatures may ultimately result in corrosion and distress to the shell via cracking, leakage and material liberation.
Implementation Method 2
The shell coating and the liner coating may be thermal barrier coatings
Data Source
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AI summary
A combustor for a gas turbine engine including a support shell (68,70) with a shell coating (170) applied thereto and a multiple of liner panels (72,74) circumferentially mounted within the support shell (68,70) via a multiple of studs, each of the multiple of liner panels (72,74) having a liner coating (140) applied thereto.