Electroformed OGV Heat Exchanger for Gas Turbine Oil Cooling
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Solution Overview
Problem
Existing gas turbine engine oil cooling systems using fan outlet guide vanes as heat exchangers face challenges in meeting oil pressure drop requirements due to limited exchange area, requiring numerous vanes and increased manufacturing complexity and cost, while also incurring fan air drag penalties.
Innovation Solution
The integration of electroformed fluid channels within heat exchanger tubes or cores disposed within airfoils in gas turbine engine guide vanes, filled with a non-flammable heat conducting liquid, which are manufactured using electroforming and investment casting methods to create a cost-effective and efficient cooling system.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If compact heat exchangers (brick coolers or surface coolers) are used for oil cooling, then cooling efficiency is improved, but fan air drag penalty increases
Solution Approach 1:
The patent combines the heat exchanger function with the fan outlet guide vane structure itself, integrating cooling channels directly into the airfoil. This merging eliminates the need for separate compact heat exchangers that would create fan air drag, while still providing effective oil cooling through the integrated channels.
Solution Approach 2:
The guide vane serves multiple functions: it directs airflow (original function) and simultaneously acts as a heat exchanger for oil cooling (additional function). This multi-functionality eliminates the need for separate cooling components that would increase fan air drag.
2Loss of energy
If OGVs are used as heat exchangers with zero fan air pressure loss, then fan air pressure loss is minimized, but the number of OGVs needed increases due to limited exchange area
Solution Approach 1:
The patent utilizes the internal volume and three-dimensional space within the OGV airfoil structure to create cooling channels. By using the thickness and internal geometry of the airfoil itself, the design maximizes heat exchange area within the existing component without adding more vanes.
3Temperature
If many OGVs are used to provide sufficient exchange area, then cooling capacity is improved, but oil pressure drop increases beyond available budget
Solution Approach 1:
The patent creates localized cooling channels within specific regions of the OGV airfoil structure. By concentrating heat exchange capability in strategic locations within each vane rather than distributing it across many vanes, the system achieves sufficient cooling capacity while maintaining acceptable oil pressure drop.
4Ease of manufacture
If electroforming method is used to manufacture OGV heat exchangers, then manufacturing complexity is reduced, but manufacturing precision requirements increase
Solution Approach 1:
The patent replaces traditional mechanical machining and assembly processes with electroforming. This substitution creates the cooling channels directly within the OGV structure through electrochemical deposition, eliminating complex mechanical manufacturing steps and reducing overall manufacturing complexity despite the precision requirements of the electroforming process itself.
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 solution enables efficient oil cooling with reduced pressure drop requirements, lower manufacturing costs, and minimizes fan air pressure loss, while providing a lightweight and durable cooling solution for gas turbine engines.
Implementation Method 1
A non-flammable heat conducting liquid may fill a space between the electroformed heat exchanger tubes or heat exchanger core and the airfoil
Implementation Method 2
The electroforming includes making a first mold of the fluid or oil channels, electrodepositing a metal or alloy on the first molds
Data Source
AI summary
A gas turbine engine guide vane heat exchanger has guide vane heat exchanger including electroformed fluid channels in electroformed heat exchanger tubes or a heat exchanger core disposed within airfoil. Non-flammable heat conducting liquid or non-metallic foam may fill space between tubes or core and airfoil. Fluid circuit may include channels within electroformed heat exchanger tubes or the heat exchanger core and extend from inlet manifold to outlet manifold for directing fluid or oil through channels and include fluid or oil supply inlet connected to inlet manifold for receiving the fluid or oil flowed into inlet manifold and a fluid or oil supply outlet connected to fluid or oil supply outlet for discharging fluid or oil flowed out of fluid or oil outlet manifold. Heat exchanger tubes or heat exchanger core, inlet manifold, outlet manifold, supply inlet and supply outlet may be integrally and monolithically electroformed together.