Effusion Cooling Hole Diameter Control via Laser Deformation

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

Existing methods for creating and maintaining effusion cooling holes in gas turbine engine combustor liners often result in excessive cooling air flow, which wastes compressor air and disrupts combustion reactions, affecting engine performance.

Innovation Solution

A method using a laser drilling tool to create effusion cooling holes, with excess material from the drilling process being deformed to reduce the hole diameter on the exit surface, ensuring the air flow meets predetermined requirements, and optionally power washing to remove debris.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If laser drilling is used to create effusion cooling holes, then manufacturing precision is improved, but the hole diameter becomes too large causing excessive air flow

Engineering Contradiction:

Improvehole diameter controlVSAvoidair flow through holes

Core Design Contradiction:

Manufacturing precisionVSQuantity of substance

Solution Approach 1:

The laser drilling process intentionally creates holes with slightly larger than final diameter, anticipating the need for subsequent size reduction. The excess material is deliberately left to be removed in a controlled manner later, rather than attempting to drill the exact final diameter in one step.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

Traditional mechanical drilling methods are replaced with laser drilling technology. The laser energy melts and vaporizes material to create holes, providing superior precision and control over hole geometry compared to mechanical drilling, while the excess material removal is achieved through controlled deformation rather than mechanical machining.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Quantity of substance

If excess material is removed from hole edges, then air flow is reduced to required levels, but additional processing steps are required

Engineering Contradiction:

Improveair flow through holesVSAvoidnumber of processing steps

Core Design Contradiction:

Quantity of substanceVSDevice complexity

Solution Approach 1:

Traditional mechanical machining methods for removing excess material are replaced with a controlled deformation process. The excess material is deformed plastically to reduce the effective hole diameter, eliminating the need for complex mechanical machining operations while achieving the required air flow reduction.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The physical state and geometry of the excess material are changed through controlled deformation. The material transitions from an excess state that creates too-large holes to a deformed state that provides the correct hole diameter for proper air flow control.

Inventive Principle:

Principle #35Parameter changes

3Quantity of substance

If hole diameter is reduced to meet flow requirements, then air flow is controlled, but combustion conditions may be adversely affected

Engineering Contradiction:

Improvecooling air flowVSAvoidcombustion reaction conditions

Core Design Contradiction:

Quantity of substanceVSReliability

Solution Approach 1:

The air flow through the effusion cooling holes is measured and used as feedback to determine whether the hole diameter is appropriate. If the air flow exceeds the predetermined level, the excess material deformation process is applied to reduce the diameter. This closed-loop control ensures that the hole size is precisely adjusted to maintain optimal combustion conditions while providing adequate cooling.

Inventive Principle:

Principle #23Feedback

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 method effectively regulates the air flow through effusion cooling holes, preventing excessive air flow and maintaining optimal combustion conditions by precisely sizing the holes, thereby enhancing engine performance.

Implementation Method 1

using a laser drilling tool to drill the hole on a first surface of the component, extending through the component and exiting from a second surface of the component, thereby forming an exiting edge of the hole with excess material melted during the drilling process remaining around the exiting edge of the hole

Methodology Applied

Scientific EffectLaser: Laser

Implementation Method 2

deforming the excess material, thereby causing a marginal reduction in an effective diameter of the hole on the second surface

Methodology Applied

Scientific EffectDeformation: Deformation

Data Source

PatentUS9089933B2Method for making and repairing effusion cooling holes in cumbustor liner

Publication Date: 2015.07.28 PRATT & WHITNEY CANADA CORP

AI summary

A method for making or repairing a laser drilled hole in a component of gas turbine engines, to meet requirements of air flow through the hole, includes deformation of an excess material melted during the laser drilling process and remaining around an opening end of the hole, thereby causing a marginal reduction in an effective diameter of the hole.