FAST-Bonded APCC Control Ring for Slow Thermal Response
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Solution Overview
Problem
Current advanced passive clearance control (APCC) systems in gas turbine engines face challenges in achieving a slow thermal response due to high mass and reduced surface areas, which are necessary for optimal performance but difficult to produce effectively.
Innovation Solution
The use of field-assisted sintering technology (FAST) to bond cover sections to wall sections, forming an enclosure that thermally isolates the control ring, creating a lightweight structure with a slow thermal response, and applying a thermal barrier coating to exterior surfaces.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Duration of action of moving object
If relatively high mass and reduced surface areas are used to achieve slow thermal response, then thermal response time is improved, but manufacturing complexity and difficulty increase
Solution Approach 1:
The control ring is divided into multiple segments that can be manufactured separately and then joined together using FAST processing. This segmentation allows each segment to be optimized for thermal response characteristics while maintaining manufacturability, resolving the contradiction between achieving slow thermal response and reducing manufacturing complexity.
Solution Approach 2:
The control ring incorporates composite material structures with varying thermal masses and surface area distributions. By using composite materials with different thermal properties in different regions, the design achieves the desired slow thermal response without requiring uniformly high mass throughout the entire structure, thereby reducing overall manufacturing complexity.
2Duration of action of moving object
If relatively high mass is used to achieve slow thermal response, then thermal response time is improved, but weight increases
Solution Approach 1:
The control ring features non-uniform mass distribution with higher thermal mass concentrated in specific regions that most effectively slow thermal response, while other regions maintain lower mass. This local quality approach achieves the desired thermal response characteristics without requiring uniformly high mass throughout the entire control ring, thereby reducing overall weight.
Solution Approach 2:
The design incorporates three-dimensional structural features such as varying wall thicknesses and internal cavities that manipulate thermal mass distribution. By utilizing dimensional variations rather than simply increasing overall mass, the control ring achieves slow thermal response through optimized thermal pathways while maintaining reduced weight.
3Duration of action of moving object
If reduced surface areas are used to achieve slow thermal response, then thermal response time is improved, but manufacturing precision requirements increase
Solution Approach 1:
By segmenting the control ring into multiple sections, the manufacturing process can focus on achieving precise surface areas for each individual segment rather than for the entire ring. This segmentation reduces the cumulative precision requirements and allows for easier adjustment and compensation during assembly using FAST processing.
Solution Approach 2:
The design incorporates adjustable geometric parameters such as wall thicknesses and segment dimensions that can be modified during manufacturing to achieve the desired surface area characteristics. These parameter changes allow for optimization of thermal response while maintaining manufacturability within standard precision tolerances.
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 approach enables the production of an improved APCC control ring that is lightweight and responsive to thermal changes, minimizing tip clearances and enhancing engine performance by forming a thermally isolated cavity and reducing response times.
Implementation Method 1
At least one of the first and second cover sections is bonded to corresponding edges of the first and second wall sections by field assisted sintering technology (FAST) processing along a bond surface to form an enclosure for the control ring
Implementation Method 2
the enclosure forms a thermally isolated cavity therein
Implementation Method 3
a thermal barrier coating (TBC) is applied to exterior surfaces of the first and second cover sections and the first and second wall sections
Data Source
AI summary
An advanced passive clearance control (APCC) control ring is provided. The APCC control ring includes first and second cover sections, first and second wall sections and a control ring. At least one of the first and second cover sections is bonded to corresponding edges of the first and second wall sections by field assisted sintering technology (FAST) processing along a bond surface to form an enclosure for the control ring.