Effusion Cooling Hole Design for Gas Turbine Plugging
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Solution Overview
Problem
Conventional effusion cooling holes in gas turbine engines are prone to plugging by fine sand and dust particles, which impede cooling efficiency and reduce component lifespan, leading to increased maintenance costs and downtime.
Innovation Solution
The design of plug-resistant effusion cooling holes with an inlet section, diverging section, and outlet configuration that positions these components external to the component's thickness, directing cooling fluid in a way that forces entrained particles towards the center, preventing accumulation and allowing for efficient heat transfer and reduced material usage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional effusion cooling holes are used, then cooling efficiency is achieved, but the holes are prone to plugging by fine sand and dust particles
Solution Approach 1:
The effusion cooling hole is divided into multiple functional sections: an inlet section with a larger diameter, a diverging section with a smallest diameter, and an outlet section. This segmentation allows each section to perform its specific function - the inlet section captures particles, the diverging section directs flow, and the outlet section maintains cooling efficiency while preventing particle accumulation.
Solution Approach 2:
Different sections of the effusion cooling hole have different diameter characteristics tailored to their specific functions. The inlet section has a larger diameter to accommodate particle-laden cooling fluid, the diverging section has a controlled smallest diameter to direct particles toward the center, and the outlet section has optimized dimensions for efficient heat transfer. This local variation in geometry prevents plugging while maintaining cooling performance.
2Temperature
If effusion cooling holes are used to regulate temperature, then cooling efficiency is improved, but fine sand and dust particles accumulate in the holes impeding cooling
Solution Approach 1:
The diverging section is designed to preliminarily direct the cooling fluid and entrained particles toward the center of the hole before the fluid reaches the outlet section. This preliminary action prevents particles from accumulating in the outlet region, ensuring that the cooling holes remain clear and maintain their temperature regulation function over time.
Solution Approach 2:
The diverging section features a curved geometry that smoothly redirects the cooling fluid and particles toward the center of the effusion cooling hole. This curved path prevents particles from adhering to the walls and accumulating, thereby maintaining cooling efficiency and reliable temperature regulation throughout the component's operational life.
3Duration of action of stationary object
If cooling features are used to reduce component temperature, then component life is extended, but fine sand and dust particles accumulate reducing cooling effectiveness
Solution Approach 1:
The effusion cooling hole design allows the cooling fluid flow itself to serve the dual function of cooling the component and preventing particle accumulation. The diverging section utilizes the natural flow dynamics to direct particles toward the center, eliminating the need for additional mechanisms and maintaining cooling effectiveness throughout the extended component lifespan.
4Loss of substance
If conventional effusion cooling holes are used, then material usage is minimized, but plugging occurs leading to increased maintenance costs and downtime
Solution Approach 1:
The effusion cooling hole geometry is optimized by changing key parameters - the inlet section has a larger diameter than conventional holes, and the diverging section creates a specific smallest diameter. These parameter changes prevent plugging while maintaining efficient heat transfer, extending component life without significantly increasing material usage.
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 configuration significantly reduces plugging by 90% compared to conventional holes, maintaining cooling efficiency and extending component life while minimizing material usage and weight.
Implementation Method 1
directing cooling fluid in a way that forces entrained particles towards the center
Implementation Method 2
maintaining cooling efficiency and extending component life
Data Source
Figure 1
Figure 2A~2B
Figure 3A~3B
AI summary
An effusion cooling hole for a component associated with a gas turbine engine extends along a longitudinal axis. The effusion cooling hole includes an inlet section spaced apart from a first surface of the component. The inlet section includes a face orientated transverse to the first surface and defines an inlet through the face that has a first diameter. The effusion cooling hole includes an outlet at a second surface of the component and downstream from the inlet section. The effusion cooling hole includes a diverging section downstream from the inlet section and upstream from the outlet. The diverging section is defined substantially external to a thickness of the component, and the effusion cooling hole transitions from the first diameter to a second diameter at the diverging section. The effusion cooling hole includes an intermediate section that fluidly connects the diverging section to the outlet.