Diffuser-Turbine Flow Network for Separation Control and Cooling
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing attritable gas turbine engines experience significant flow separation in the compressor diffuser airfoil section, which negatively impacts performance, and post-processing of diffuser vanes is challenging due to additive manufacturing complexities.
Innovation Solution
A compressor diffuser vane and turbine nozzle vane flow network is designed with suction points, suction flow passages, a main artery, and film holes to maintain airflow attachment and provide cooling, utilizing additive manufacturing to integrate these features for improved airflow management and thermal protection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If additive manufacturing is used to create a unitized compressor diffuser vane configuration, then manufacturing complexity is reduced and production efficiency is improved, but flow separation occurs in the compressor diffuser airfoil section which negatively impacts performance
Solution Approach 1:
The patent extracts the flow control function from the traditional diffuser vane design by adding a separate suction flow passage system. This suction system actively removes boundary layer air from the suction side of the airfoil, preventing flow separation while maintaining the additive manufactured unitized structure. The suction points and flow passages are integrated into the additive manufactured component, separating the flow control function from the structural function.
Solution Approach 2:
The patent applies pneumatic principles by using a suction flow passage system to control airflow attachment. Compressor discharge air is routed through suction flow passages to suction points on the suction side of the diffuser vane, creating a low-pressure region that actively prevents flow separation. This pneumatic flow control mechanism resolves the contradiction between the simplified additive manufactured structure and the need for reliable flow attachment.
2Ease of manufacture
If additive manufacturing is used for the diffuser vane, then part count is reduced and manufacturing is simplified, but post processing becomes very challenging
Solution Approach 1:
The patent merges multiple functions into the single additive manufactured diffuser vane component: structural support, flow guidance, and active flow control through integrated suction flow passages. By combining these functions into one unitized structure, the design eliminates the need for separate post-processing operations on multiple components, making the overall manufacturing process simpler despite the complexity of the integrated features.
Solution Approach 2:
The additive manufactured diffuser vane serves multiple functions simultaneously: it provides the structural airfoil shape for flow guidance, incorporates suction points for active flow control, and includes internal suction flow passages for pneumatic flow management. This multi-functionality reduces the total part count and eliminates the need for complex post-processing assembly operations.
3Power
If turbine nozzle vane is exposed to hot gases, then energy extraction is maximized, but thermal stress reduces turbine vane life
Solution Approach 1:
The patent introduces an intermediary cooling system between the hot gases and the turbine nozzle vane structure. Compressor discharge air is routed through a main artery and into cooling passages within the turbine nozzle vane, acting as a cooling medium that absorbs thermal energy from the hot gas path. This intermediary cooling air flow reduces thermal stress on the vane while allowing continued exposure to hot gases for energy extraction.
Solution Approach 2:
The patent changes the thermal parameters of the turbine nozzle vane by introducing cooling air flow through internal passages. The cooling air absorbs thermal energy from the vane structure, reducing its temperature and thermal stress. This parameter change (temperature reduction) extends the duration of action (service life) of the stationary turbine vane while maintaining its ability to extract energy from hot gases.
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 flow network prevents flow separation and enhances cooling, leading to improved engine performance, efficiency, and extended turbine vane life by maintaining airflow attachment and reducing thermal stress.
Implementation Method 1
significant flow separation occurring in the compressor diffuser airfoil section which negatively impacts performance
Implementation Method 2
suction points and suction flow passages that remove boundary layer air from the suction side
Implementation Method 3
main artery formed within an outer platform, the outer platform in operative communication with the compressor diffuser vane, the main artery formed within the turbine nozzle vane
Implementation Method 4
air flowing within the main artery removes thermal energy from the turbine nozzle vane, the thermal energy being produced from exposure to hot gases flowing across the turbine nozzle vane
Implementation Method 5
at least one film hole being configured to produce a film layer over the inner platform providing an insulating protective function from hot gases flowing toward a turbine section
Data Source
Figure 1
Figure 2
Figure 3
AI summary
A gas turbine engine comprising a compressor diffuser vane (120) and turbine nozzle vane (82), at least one suction point (134) being formed in a suction side of the compressor diffuser vane, a suction flow passage (140) fluidly coupling the at least one suction point with a main artery (138) having a first portion formed in a wall (80) extending between an inner end of the compressor diffuser vane and an outer end of the turbine nozzle vane, said wall forming an outer platform of the turbine nozzle vane; a second portion formed within the turbine nozzle vane; and a third portion formed within a radially inner platform of the turbine nozzle vane, said portions being in fluid communication. A film hole passage (142) fluidly couples the main artery to at least one film hole (136) formed in the inner platform, the at least one film hole fluidly coupled to the main artery.