Cooling Aperture Inspection for Meter-Diffuser Alignment

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Solution Overview

Problem

Existing methods for forming and inspecting cooling apertures in turbine engine components are inadequate, particularly in ensuring precise alignment and alignment of meter and diffuser sections, which affect cooling efficiency.

Innovation Solution

A method for inspecting fluid cooled components using non-contact, non-destructive imaging systems, such as microwave imaging, to determine the alignment of meter and diffuser sections, followed by precise machining to align these sections accurately.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Measurement precision

If conventional inspection methods are used for cooling apertures, then the inspection process is simple, but the alignment precision of meter and diffuser sections cannot be ensured

Engineering Contradiction:

Improvealignment precision of meter and diffuser sectionsVSAvoidinspection system complexity

Core Design Contradiction:

Measurement precisionVSDevice complexity

Solution Approach 1:

The patent replaces conventional mechanical inspection methods with microwave imaging technology. The microwave imaging system uses electromagnetic waves to penetrate the thermal barrier coating and capture images of the cooling aperture sections, enabling non-contact, non-destructive measurement of alignment precision without requiring physical access or complex mechanical measurement apparatus.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent introduces microwave waves as an intermediary medium to inspect the cooling aperture alignment. The microwave imaging system transmits microwave signals through the component material and coating layers, capturing internal structural information about the meter and diffuser section alignment without direct physical contact, thus achieving precise measurement while avoiding the complexity of mechanical inspection systems.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Reliability

If thermal barrier coating is applied to protect the component, then the component durability is improved, but the inspection of cooling aperture alignment becomes difficult

Engineering Contradiction:

Improvecomponent durabilityVSAvoiddifficulty of inspecting cooling aperture alignment

Core Design Contradiction:

ReliabilityVSDifficulty of detecting and measuring

Solution Approach 1:

The patent replaces mechanical inspection methods with microwave imaging technology. The microwave imaging system uses electromagnetic waves to penetrate the thermal barrier coating and capture images of the cooling aperture sections, enabling non-contact, non-destructive measurement of alignment precision without requiring physical access or complex mechanical measurement apparatus.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent changes the inspection parameter from mechanical contact-based measurement to electromagnetic wave-based imaging. By using microwave waves with specific frequency parameters, the system can penetrate the thermal barrier coating material and obtain images of the underlying cooling aperture structure, allowing inspection of alignment without removing or damaging the protective coating.

Inventive Principle:

Principle #35Parameter changes

3Measurement precision

If non-contact imaging systems are used to inspect cooling apertures, then the inspection process is non-destructive, but the alignment precision may be insufficient

Engineering Contradiction:

Improvealignment precisionVSAvoidinspection reliability

Core Design Contradiction:

Measurement precisionVSReliability

Solution Approach 1:

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent employs feedback mechanisms in the microwave imaging process. The system captures microwave-based images of the cooling aperture alignment, processes this information to identify misalignments between meter and diffuser sections, and provides feedback that guides subsequent machining operations to achieve precise alignment, thereby ensuring both non-destructive inspection and high measurement precision.

Inventive Principle:

Principle #23Feedback

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

Ensures precise alignment of meter and diffuser sections, enhancing cooling efficiency and reliability of turbine engine components.

Implementation Method 1

using non-contact, non-destructive imaging systems, such as microwave imaging

Methodology Applied

Scientific EffectMicrowave imaging: Microwave Radiation

Data Source

PatentEP4134519B1Method for inspecting cooling apertures in a turbine engine component

Publication Date: 2026.03.25 RTX CORP

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AI summary

A manufacturing method is provided. During this method, a preform component (60') for a turbine engine is provided that includes a substrate (74). A meter section (102) of a cooling aperture (64) is formed in the substrate (74'). An external coating (76',78') is applied over the substrate. At least a portion of the substrate (74') and the external coating (76',78') is scanned with an imaging system (156) to provide scan data indicative of an internal structure of the portion of the substrate (74') and the external coating (76',78'). A diffuser section of the cooling aperture is formed in the external coating (76',78') and the substrate (74') based on the scan data.