Cooling Aperture Machining for Turbine Coating-Substrate Alignment

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Solution Overview

Problem

Existing methods for forming cooling apertures in turbine engine components are limited in efficiency and precision, particularly in combining different machining processes for diffuser and meter sections within conductive and non-conductive materials.

Innovation Solution

A manufacturing method involving a preform component with a substrate and outer coating, where the diffuser section is formed using a first machining process (such as laser machining) and the meter section is formed using a second distinct machining process (like electrical discharge machining), optimizing the geometry and alignment of cooling apertures through the substrate and coatings.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If a single machining process is used to form both diffuser and meter sections, then the manufacturing process is simpler, but the precision and efficiency of cooling aperture formation deteriorates

Engineering Contradiction:

Improvemanufacturing process simplicityVSAvoidcooling aperture precision

Core Design Contradiction:

Ease of manufactureVSManufacturing precision

Solution Approach 1:

The cooling aperture formation process is segmented into two distinct machining operations: a first machining process forms the diffuser section, and a second machining process forms the meter section. This segmentation allows each section to be optimized with the most appropriate machining method, thereby improving overall manufacturing precision while maintaining reasonable process complexity.

Inventive Principle:

Principle #1Segmentation

2Productivity

If laser machining is used for the diffuser section, then the efficiency of machining through coating and substrate is improved, but the precision of the meter section deteriorates

Engineering Contradiction:

Improvediffuser section machining efficiencyVSAvoidmeter section precision

Core Design Contradiction:

ProductivityVSManufacturing precision

Solution Approach 1:

Different machining processes are applied to different sections of the cooling aperture based on their specific requirements. The diffuser section, which requires efficient removal of coating and substrate material, is machined using laser machining. The meter section, which requires high precision, is machined using a different process. This local quality approach ensures optimal performance for each section.

Inventive Principle:

Principle #3Local quality

3Manufacturing precision

If electrical discharge machining is used for the meter section, then the precision of the meter section is improved, but the overall manufacturing time increases

Engineering Contradiction:

Improvemeter section precisionVSAvoidtotal manufacturing time

Core Design Contradiction:

Manufacturing precisionVSLoss of time

Solution Approach 1:

The manufacturing process is segmented so that the time-consuming high-precision electrical discharge machining is applied only to the meter section, while the diffuser section is machined more quickly using laser machining. This segmentation minimizes the total manufacturing time while still achieving the required precision for the critical meter section.

Inventive Principle:

Principle #1Segmentation

4Manufacturing precision

If cooling aperture formation is performed after coating application, then the alignment between substrate and coating is improved, but the complexity of the manufacturing process increases

Engineering Contradiction:

Improvesubstrate-coating alignmentVSAvoidmanufacturing process complexity

Core Design Contradiction:

Manufacturing precisionVSDevice complexity

Solution Approach 1:

The coating is applied to the substrate before the cooling aperture is formed. This preliminary action ensures that the coating and substrate are perfectly aligned before any machining occurs. The subsequent machining process then forms the cooling aperture through both the coating and substrate in one operation, maintaining their alignment while avoiding the need for additional alignment steps.

Inventive Principle:

Principle #10Preliminary action

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

This approach enhances the precision and efficiency of cooling aperture formation, improving fluid flow and thermal management in turbine engine components by ensuring precise alignment and efficient machining of both conductive and non-conductive materials.

Implementation Method 1

The first machining process may be or include a laser machining process

Methodology Applied

Scientific EffectLaser machining: Laser Ablation

Implementation Method 2

The second machining process may be or include an electrical discharge machining process

Methodology Applied

Scientific EffectElectrical discharge machining: Electrical Discharge Machining

Data Source

PatentUS20230052285A1Forming cooling aperture(s) in a turbine engine component

Publication Date: 2023.02.16 RTX CORP

AI summary

A manufacturing method is provided. During this method, a preform component for a turbine engine is provided. This preform component includes a substrate and an outer coating on the substrate. A cooling aperture is formed in the preform component. The cooling aperture includes a diffuser section and a meter section. The diffuser section extends through the outer coating and into the substrate. The meter section extends within the substrate. The forming of the cooling aperture includes: forming the diffuser section using a first machining process; and forming the meter section using a second machining process that is different than the first machining process.