Curved Nozzle Sector Geometry for Stable DMLM Turbine Stators
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Solution Overview
Problem
Nozzle sectors in gas turbine stators suffer from deformation due to thermal gradients and loading stresses, leading to reduced useful life, friction, increased clearances, and efficiency loss, and require larger additive manufacturing printers.
Innovation Solution
A nozzle sector design with Z- or S-shaped sidewall edges and optimized angles allows for reduced width and improved dimensional stability, processed through Direct Metal Laser Melting (DMLM) to minimize deformation and reduce manufacturing time and costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the nozzle sector width is reduced to enable printing on standard additive manufacturing printers, then the manufacturing cost and accessibility are improved, but the structural stability and resistance to deformation under thermal gradients and loading stresses deteriorate
Solution Approach 1:
The patent applies curved S-shaped or Z-shaped sidewall edges instead of straight edges. This curvature allows the platform to rotate and deform in a controlled manner under thermal and mechanical loads, reducing gaps between adjacent nozzle sectors while maintaining a compact width suitable for standard additive manufacturing printers.
Solution Approach 2:
The patent optimizes specific geometric parameters including the angles of the curved sidewall edges (first and second angles relative to the platform leading and trailing edges), the distance between platforms and airfoil edges, and the overall platform dimensions. These parameter optimizations ensure dimensional stability and resistance to deformation despite the reduced width.
2Reliability
If the platform sidewall edges are tilted to accommodate airfoil shape and ensure sector life, then the structural integrity is improved, but the width of the nozzle sector increases requiring larger additive manufacturing printers
Solution Approach 1:
The curved S-shaped or Z-shaped sidewall edges enable the platform to rotate and deform controllably under load, maintaining structural integrity and reducing gaps between sectors while keeping the circumferential width compact for standard printer compatibility.
Solution Approach 2:
The patent designs the platform with dynamic capability to rotate in response to airfoil loading. The curved sidewall edges facilitate this rotation, allowing the structure to adapt to thermal and mechanical stresses while maintaining reliability without increasing width.
3Productivity
If the nozzle sector width is reduced, then the additive manufacturing time and material costs are decreased, but the deformation under thermal gradients and loading stresses increases
Solution Approach 1:
The S-shaped or Z-shaped curved sidewall edges are specifically designed to control deformation behavior. When the platform rotates under thermal and mechanical loads, these curved edges ensure that deformation is distributed and controlled, preventing excessive gaps and maintaining structural stability despite the reduced width that enables faster, cheaper manufacturing.
4Stability of the object's composition
If the platform is designed with larger distance from ending portions to airfoil leading and trailing edges to reduce deformation, then the structural stability is improved, but the width of the nozzle sector increases
Solution Approach 1:
The curved sidewall edges create an optimized stress distribution pattern that enhances dimensional stability without requiring increased width. The S-shaped or Z-shaped geometry allows the structure to better accommodate thermal gradients and loading stresses within a compact circumferential dimension.
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 design achieves greater stability, reduces manufacturing time and costs, and enhances efficiency by minimizing deformation and clearance issues while using standard additive manufacturing printers.
Implementation Method 1
processed through Direct Metal Laser Melting (DMLM)
Implementation Method 2
processed through Direct Metal Laser Melting (DMLM)
Data Source
AI summary
A nozzle sector for a sectorized annular stator of a gas turbine, comprising an inner platform and an outer platform, said inner platform and said outer platform being substantially concentric with respect to turbine rotational axis and spaced apart from each other by at least an airfoils, wherein each one of said inner platform and said outer platform has a platform leading edge, a platform trailing edge and a first and a second platform sidewall edge, each one of said sidewall edges being extending from said platform leading edge to said platform trailing edge of the respective platform, wherein each one of said first and said second sidewall edges has a leading portion, a trailing portion, and an intermediate portion comprised between said leading portion and said trailing portion.