Cooling Patch Channels for Gas Turbine Hot Spot Protection
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Solution Overview
Problem
Hot gas path components in gas turbine engines face thermal stress and damage due to inadequate cooling, particularly in localized hot spots, which can reduce their lifespan and impact system efficiency and power output.
Innovation Solution
A cooling patch comprising a base layer with cooling channels made from pre-sintered preform material, attached to the cold side of hot gas path components, which directs airflow through the channels to provide film cooling and enhance heat transfer, using a filter to prevent debris and maintain pressure-driven airflow.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If higher temperature combustion flows are used to increase performance and power output, then the efficiency and power output of the gas turbine engine increase, but the hot gas path components are subjected to thermal stress and damage that reduces their lifespan
Solution Approach 1:
The cooling system is divided into multiple independent cooling channels within the bond pad, allowing separate control of coolant flow to different regions of the hot gas path component. This segmentation enables targeted cooling of specific hot spots while maintaining overall component integrity under high temperature combustion flows
Solution Approach 2:
A cooling bond pad is introduced as an intermediary component between the hot gas path component and the coolant source. This bond pad with embedded cooling channels acts as a thermal interface that transfers heat from the component to the coolant, protecting the component from direct thermal stress while allowing the component to operate at high temperatures for improved power output
2Reliability
If cooling channels are added to cool hot gas path components, then component lifespan is extended, but the device complexity increases
Solution Approach 1:
The cooling channels are merged into a single integrated cooling bond pad that can be attached to the hot gas path component. This consolidation of multiple cooling functions into one component reduces overall system complexity compared to having separate cooling systems for each component, while still providing extended component lifespan through effective cooling
Solution Approach 2:
The cooling bond pad utilizes porous material structure to facilitate coolant distribution through the cooling channels. The porous nature of the material allows for efficient coolant flow and heat transfer while maintaining a relatively simple geometric structure, reducing manufacturing complexity while achieving reliable cooling
3Temperature
If internal cooling channels are used to cool components, then cooling effectiveness is improved, but manufacturing precision requirements increase
Solution Approach 1:
The manufacturing approach changes from machining precise cooling channels into solid components to forming channels within a porous preform material. This parameter change in material state and formation process significantly reduces manufacturing precision requirements while maintaining effective cooling channels that improve temperature control of the hot gas path component
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 cooling patch effectively extends the lifespan of hot gas path components by reducing local temperatures and heat transfer coefficients without impacting overall system power or efficiency, allowing for flexible installation at any time.
Implementation Method 1
directs airflow through the channels to provide film cooling and enhance heat transfer
Implementation Method 2
base layer with cooling channels made from pre-sintered preform material, attached to the cold side of hot gas path components
Data Source
Figure 1~2
Figure 3~4
AI summary
The present application provides a cooling patch (10) for use with a hot gas path component (110) of a gas turbine engine (10). The cooling patch (100) may include a base layer (120) with a number of cooling channels (140) extending therethrough, and a cover layer (130) positioned on the base layer (120). The base layer (120) and the cover layer (130) may include a pre-sintered preform material.