Contoured Thermal Barrier Coating for Combustor Liner Distress
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Solution Overview
Problem
Gas turbine combustors experience liner distress due to air jets in cross-flow, which disrupt cooling and increase heat transfer, leading to oxidation and melting of combustor materials, caused by complex flow interactions and non-uniform fuel-air distributions.
Innovation Solution
A contoured surface is applied to the thermal barrier coating and base metal around holes in the combustor liner, with varying thicknesses to create a protruding or bump-out surface that manages the flow field and reduces panel distress, formed during casting or fabrication, and can be uniform or non-uniform around the hole.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If air feed holes are provided to support combustion, then combustion performance is improved, but liner distress (oxidation) occurs due to air jet in cross-flow
Solution Approach 1:
The contoured surface is formed in advance during casting or fabrication, before the combustor operates. This pre-formed geometry modifies the flow field upstream of the holes to prevent the formation of harmful air jets and secondary flows that would otherwise cause liner distress
Solution Approach 2:
The solution transitions from a flat, two-dimensional liner surface to a three-dimensional contoured surface with varying thickness. This dimensional change allows the surface to actively manage and redirect the flow field around the holes, controlling the complex fluid dynamics that cause liner distress
2Object-affected harmful factors
If dilution holes are provided to tailor combustion, then emissions are improved, but heat transfer increases causing localized overheating
Solution Approach 1:
The thermal barrier coating is applied with locally varying thickness rather than uniform thickness. The coating is thicker in regions where heat transfer is elevated due to dilution holes, providing enhanced thermal protection precisely where needed without adding unnecessary weight or complexity elsewhere
3Stability of the object's composition
If trim holes are provided to control combustion, then combustion stability is improved, but secondary flows disrupt cooling causing material melting
Solution Approach 1:
The contoured surface geometry is pre-formed during manufacturing to anticipate and prevent the formation of harmful secondary flows. By shaping the surface upstream of the trim holes, the design proactively guides the flow to avoid creating vortical structures that would disrupt cooling and threaten material integrity
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 contoured surface effectively controls and manages the flow field, reducing the extent of liner distress and heat transfer, thereby minimizing oxidation and melting of combustor materials, providing a cost-effective solution for managing flow fields around holes.
Implementation Method 1
thermal barrier coating of a combustor dilution hole
Implementation Method 2
reducing the extent of liner distress and heat transfer
Data Source
AI summary
Aspects of the disclosure are directed to a liner associated with a combustor of an aircraft engine, comprising: a thermal barrier coating, and a base metal, wherein the thermal barrier coating comprises a contoured surface on a flowpath side proximate to an exit of a hole formed by the thermal barrier coating and the base metal.