Cooling Aperture Machining for Coated Turbine Engine Components
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Solution Overview
Problem
Existing methods for forming cooling apertures in gas turbine engine components are not optimized for efficient fluid flow and thermal management, leading to suboptimal performance.
Innovation Solution
A manufacturing method involving a preform component with a conductive substrate and non-conductive outer coating, where a preform aperture is created using electrical discharge machining, including a meter section in the substrate and a pilot hole in the coating, with a diffuser section formed in the coating using a secondary machining process to enhance fluid flow and thermal management.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a single machining process is used to form cooling apertures in both substrate and outer coating, then the manufacturing process is simple, but the aperture geometry cannot be optimized for efficient fluid flow and thermal management
Solution Approach 1:
The cooling aperture formation process is segmented into two distinct stages: first forming a preform aperture in the substrate using electrical discharge machining, then forming the final aperture geometry by removing outer coating material over the preform aperture. This segmentation allows each stage to be optimized independently for its specific function.
Solution Approach 2:
The preform aperture is created in advance within the substrate before the outer coating is removed. This preliminary action establishes the core geometry and fluid flow path, which then guides the subsequent coating removal process to achieve the final optimized aperture shape.
2Manufacturing precision
If electrical discharge machining is used to form the preform aperture in the substrate, then precise meter section geometry is achieved, but the outer coating cannot be machined with the same process
Solution Approach 1:
The preform aperture acts as an intermediary structure that mediates between the electrical discharge machining process (optimized for conductive substrate) and the final aperture geometry (requiring outer coating removal). It provides a template that guides the subsequent coating removal while being created by a process incompatible with the coating material.
3Productivity
If the outer coating is removed to form the diffuser section, then fluid flow efficiency is improved, but the coating material is wasted
Solution Approach 1:
The outer coating is selectively removed in the diffuser section region to create a porous or open structure that allows fluid flow, while preserving the coating in other regions where it provides protective or functional benefits. This targeted removal optimizes fluid flow without completely sacrificing the coating material.
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 improves the formation of cooling apertures, enhancing fluid flow and thermal management in turbine engine components, leading to improved performance and efficiency.
Implementation Method 1
A preform aperture is formed in the preform component using an electrical discharge machining electrode
Implementation Method 2
Fluid is directed through a bore of the electrode against a backside of the outer coating to form a pilot hole in the outer coating
Implementation Method 3
A diffuser section of the cooling aperture is formed in at least the outer coating using a laser machining process
Data Source
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AI summary
A manufacturing method is provided. During this method, a preform component (60') is provided for a turbine engine. The preform component includes a substrate (74') comprising electrically conductive material having an outer coating (78') comprising non-electrically conductive material applied over a surface of the substrate. A preform aperture is formed in the preform component using an electrical discharge machining electrode (144). The preform aperture includes a meter section (102) of a cooling aperture (64) in the substrate. The preform aperture also includes a pilot hole (152) in the outer coating. A diffuser section (104) of the cooling aperture is formed in at least the outer coating using a second machining process.