Gas Turbine Cooling Channels with Merged Exit Regions
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Solution Overview
Problem
Current micro-channel cooling techniques for gas turbine engines require the formation of numerous exit holes for each micro-channel, increasing manufacturing costs due to the complexity and time-consuming process of creating hundreds of individual film exit holes.
Innovation Solution
A substrate with grooves and access holes connected to a hollow interior space, coated with layers forming channels, and trenches in the coating to define exit regions, simplifying the formation of exit regions and reducing the need for precision location of individual film holes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If individual film exit holes are formed for each micro-channel, then cooling efficiency is improved, but manufacturing complexity and cost increase significantly
Solution Approach 1:
Multiple individual film exit holes are merged into a single common exit region that serves multiple micro-channels. This consolidation maintains the cooling function while dramatically reducing the number of precision holes that need to be formed, thereby lowering manufacturing complexity and cost.
Solution Approach 2:
The common exit region serves as a universal exit for multiple micro-channels, replacing the need for individual dedicated exit holes for each channel. This multi-functional design maintains effective cooling while simplifying the overall structure and manufacturing process.
2Manufacturing precision
If individual film exit holes are formed for each micro-channel, then precise coolant delivery is improved, but manufacturing time and cost increase
Solution Approach 1:
Multiple precision-critical individual exit holes are combined into a single common exit region, reducing the total number of precision features that must be manufactured. This maintains adequate coolant delivery precision while significantly improving manufacturing speed and reducing cost.
3Ease of manufacture
If traditional cooling passages are used, then manufacturing simplicity is maintained, but heat transfer rates and cooling efficiency are reduced
Solution Approach 1:
The invention transitions from traditional three-dimensional internal cooling passages to a two-dimensional surface-level micro-channel network with a common exit region. This dimensional change enables much higher heat transfer rates through the micro-channel structure while maintaining relative manufacturing simplicity through the consolidated exit design.
Solution Approach 2:
The invention changes the geometric parameters of the cooling structure by implementing micro-scale channel dimensions and a consolidated exit region configuration. These parameter changes enable enhanced heat transfer rates while keeping the manufacturing process relatively simple compared to traditional individual exit hole approaches.
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 reduces manufacturing costs and enhances cooling efficiency by maintaining coolant in close contact with the hot surface, improving heat transfer rates and uniformity of temperature profiles.
Implementation Method 1
the cooling fluid may flow through the passages, cooling the hot gas path component substrate and coatings
Implementation Method 2
One or more trenches are formed through one or more layers of the coating and at least partially define at least one exit region for the one or more cooling channels
Data Source
AI summary
A component is disclosed. The component includes a substrate comprising an outer surface and an inner surface. The inner surface defines at least one hollow, interior space, and the outer surface defines one or more grooves that extend at least partially along the outer substrate surface and have a respective base. One or more access holes are formed through the base of a respective groove, to connect the groove in fluid communication with the respective hollow interior space. The component further includes a coating comprising one or more layers disposed over at least a portion of the outer substrate surface. The groove(s) and the coating together define one or more channels for cooling the component. One or more trenches are formed through one or more coating layers and at least partially define at least one exit region for the cooling channel(s). A method of fabricating a component is also provided.