Additive Manufactured Engine Case with Internal Cooling Passages
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Solution Overview
Problem
Existing gas turbine engine designs face challenges in achieving a lightweight yet strong structure for blade containment, efficient cooling, and effective temperature control, often resulting in increased manufacturing complexity and weight due to external piping systems.
Innovation Solution
The use of additive manufacturing techniques to create an internal cooling circuit within the engine casing, featuring an internal annular passage with a pin bank and turbulation features, which allows for controlled temperature management and reduced weight by eliminating the need for external cooling systems.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If external piping systems are used for cooling and temperature control, then cooling effectiveness is improved, but device complexity and weight increase
Solution Approach 1:
The patent merges the cooling function and temperature control function into the engine case structure itself by forming internal fluid passages directly within the case walls. This integration eliminates the need for separate external piping systems, manifolds, and associated components, thereby reducing device complexity while maintaining effective temperature control through the internally integrated fluid circulation paths.
2Temperature
If external piping systems are used for cooling, then cooling effectiveness is improved, but weight increases
Solution Approach 1:
The cooling and temperature control functions are merged into the engine case structure by forming internal fluid passages within the case walls. This integration eliminates the weight of external piping systems, manifolds, brackets, and valves, reducing the overall weight of the stationary engine case while maintaining effective cooling through the internally integrated fluid circulation paths.
3Weight of stationary object
If additive manufacturing with internal passages is used, then weight is reduced and strength is improved, but manufacturing complexity increases
Solution Approach 1:
The patent employs additive manufacturing technology to create the engine case with internal fluid passages, representing a fundamental change in the manufacturing parameter from traditional subtractive or assembly methods. This parameter change enables the formation of complex internal cooling and temperature control passages within the case structure, reducing weight and improving strength through optimized material distribution while the additive process itself manages the manufacturing complexity.
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 enhances structural integrity, reduces weight, improves cooling efficiency, and maintains effective temperature control without the complexity and weight of external systems, ensuring optimal performance and longevity of engine components.
Implementation Method 1
Impingement cooling is frequently employed in ACC systems to control the temperature of the engine casing. The internal cooling circuit allows fluid to flow through passages in the engine casing, transferring heat from the casing to the cooling fluid.
Implementation Method 2
Through control of the engine case temperature using the internal cooling circuit, ACC control may be possible. The cooling circuit conducts heat away from the engine casing to maintain proper temperature distribution.
Implementation Method 3
The internal cooling circuit, may be used, along with other benefits, to control the temperature of the engine case. Pin banks and turbulation features are included to enhance heat transfer by creating turbulent flow and disrupting thermal boundary layers.
Data Source
AI summary
An engine or engine casing having an inner annular case and an outer annular case. The engine casing is formed using an additive manufacturing technique such that the inner annular case and outer annular case is formed surrounding a hollow inner annular cavity. The annular cavity includes a pin bank connecting the inner annular case and outer annular case. The pin bank improves heat transfer between the inner and outer annular case and provide structural support to the inner and outer annular case. By providing fluid flow through the annular cavity, the turbine casing can be cooled and the radius of the casing can be controlled through the regulation of fluid travelling within the annular cavity. By controlling the fluid flow though the annular cavity, the engine case may be cooled to regulate its temperature in a wide variety of operating conditions. Further, the regulation of fluid in the annular cavity allows for active clearance control of the spacing between the turbine blades or vanes and seals used in the turbine.