Encapsulated Diffuser Insert for Turbine Cooling
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Solution Overview
Problem
Existing cooling systems for turbine components suffer from inadequate coolant coverage, leading to excessively high surface temperatures and reduced part life, necessitating increased cooling fluid usage.
Innovation Solution
A method involving an encapsulated diffuser insert with a central passageway of circular cross-section and an elongated rectangular exit, partially inserted into a turbomachine part, coated with a thermal barrier coating, and secured with a sacrificial cap that allows unobstructed airflow, enhancing coolant distribution and efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional cooling systems are used with multiple cooling holes, then coolant coverage can be improved, but device complexity and manufacturing difficulty increase
Solution Approach 1:
The cooling system is segmented into multiple cooling holes distributed across the turbine blade, each contributing to overall coolant coverage. This segmentation allows systematic distribution of cooling function across multiple locations rather than relying on a single complex structure.
Solution Approach 2:
The diffuser insert is nested within the turbine blade structure, with cooling holes formed inside the blade body and the diffuser insert positioned within this internal cooling passage network. This nesting integrates the diffuser functionality within the existing blade architecture.
2Temperature
If cooling flow is increased to protect turbine components, then component temperature is managed, but turbine efficiency decreases
Solution Approach 1:
The diffuser insert modifies the local flow characteristics at specific cooling hole locations to improve coolant distribution efficiency. By optimizing the flow pattern locally at each cooling hole exit, the system achieves better temperature management with potentially reduced overall cooling flow requirements.
Solution Approach 2:
The diffuser insert changes the flow parameters of the coolant as it exits the cooling holes, transforming the flow from a narrow jet to a broader diffused pattern. This parameter change in flow distribution improves heat transfer effectiveness and reduces the total cooling flow needed to achieve the same thermal protection.
3Power
If firing temperature is increased to improve efficiency, then power generation increases, but turbine component damage risk increases
Solution Approach 1:
The diffuser insert is pre-installed within the turbine blade during manufacturing, establishing the optimized cooling flow pattern before the turbine operates at high temperatures. This preliminary configuration ensures that when high firing temperatures are applied, the cooling system is already optimized to protect the components.
Solution Approach 2:
The diffuser insert acts as an intermediary element between the cooling holes and the external environment, modifying the coolant flow pattern to improve heat transfer. This intermediary structure enhances the protective function of the cooling system, allowing higher operating temperatures without increasing component damage risk.
4Reliability
If thermal barrier coating is applied to encapsulate the diffuser insert, then protective function is improved, but manufacturing complexity increases
Solution Approach 1:
The manufacturing process is segmented into distinct sequential steps: first forming the cooling holes and installing the diffuser insert, then applying the thermal barrier coating. This segmentation of manufacturing operations allows each step to be optimized independently, reducing overall manufacturing complexity despite the multi-step process.
Solution Approach 2:
The diffuser insert is preliminarily installed within the turbine blade before the thermal barrier coating is applied. This preliminary installation ensures that the coating can be applied uniformly over the external surfaces without interfering with the internal diffuser structure, simplifying the coating application process.
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 solution provides improved cooling coverage, reduces surface temperatures, increases turbine efficiency, and extends part life by optimizing airflow and reducing the number of cooling holes required, allowing for higher firing temperatures and increased power generation with less fuel and wear.
Implementation Method 1
A coating step is used for coating the turbomachine part with a thermal barrier coating to at least partially encapsulate the encapsulated diffuser insert in the thermal barrier coating
Implementation Method 2
cooling fluid may be directed in and/or onto the turbine components. Component temperature can then be managed through a combination of impingement onto the component, cooling flow through passages in the component
Implementation Method 3
cooling flow through passages in the component
Data Source
AI summary
A method of forming a cooling assembly in a turbomachine part is provided. The method includes placing an encapsulated diffuser insert partially into a hole in the turbomachine part. The encapsulated diffuser insert has an unobstructed central passageway with a generally circular cross-section at a first end and an elongated rectangular cross-section at a second end opposing the first end. The second end has a sacrificial cap. A coating step coats the turbomachine part to at least partially encapsulate the encapsulated diffuser insert in a coating. A removing step removes the sacrificial cap to enable air flow through the central passageway. The encapsulated diffuser insert remains in the hole of the turbomachine part and the coating, thereby providing the unobstructed central passageway with a generally circular first end and an elongated rectangular second end adjacent to an outer surface of the turbomachine part.