Gas Turbine Tile Triangular Support Body Additive Manufacturing
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Solution Overview
Problem
Additive manufacturing of combustion chamber tiles for gas turbines often results in residual stresses and cracking due to sudden geometric changes in thickness, which can be exacerbated by support structures that either increase component volume or require costly removal.
Innovation Solution
A support body with a triangular cross-section and slot-like recesses is integrated between the base body and edge strip, featuring cooling air holes and a rib-like structure to manage stress and facilitate effective cooling, reducing the risk of cracking and improving manufacturability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If support structures are used to manage thickness transitions during additive manufacturing, then residual stresses and cracking are reduced, but component volume increases and cooling efficiency deteriorates
Solution Approach 1:
The support body is designed with slot-like recesses that create a rib-like structure with controlled porosity. This porous configuration reduces material accumulation while maintaining structural support function during manufacturing and enabling cooling functionality, thus resolving the contradiction between providing support and minimizing volume.
Solution Approach 2:
Material is strategically removed from the support body by creating slot-like recesses, transforming it from a solid structure to a rib-like porous structure. This extraction reduces the overall volume and creates cooling pathways while preserving the essential support function for the edge strip transition.
2Reliability
If support structures are used to manage thickness transitions during additive manufacturing, then residual stresses and cracking are reduced, but cooling efficiency deteriorates
Solution Approach 1:
The slot-like recesses create a porous rib-like structure that inherently provides cooling pathways. The porosity allows cooling media to flow through the support body, transforming what would be a cooling barrier into a cooling facilitator, thus resolving the contradiction between structural support and cooling efficiency.
Solution Approach 2:
The support body, which initially appears to be a harmful obstacle to cooling due to material accumulation, is transformed into a beneficial cooling structure through the slot-like recesses. The same structural element that provides mechanical support also serves as a cooling conduit, converting the potential harm into benefit.
3Volume of stationary object
If support structures are removed after manufacturing, then component volume is reduced, but production cost increases and residual stresses may still cause cracking
Solution Approach 1:
The support body is designed to serve multiple functions simultaneously: providing structural support during manufacturing, enabling cooling functionality through slot-like recesses, and eliminating the need for post-manufacturing removal. This multi-functionality resolves the contradiction by making the support structure permanently beneficial rather than a temporary aid that requires costly removal.
Solution Approach 2:
The support body with slot-like recesses is self-sufficient and does not require external intervention for removal. It performs its support function during manufacturing and then continues to serve as a functional part of the component, providing cooling pathways. The structure serves itself throughout the entire product lifecycle, eliminating the need for costly post-processing removal operations.
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 design minimizes residual stresses, enhances cooling efficiency, and allows for the production of components with complex geometries using additive manufacturing, particularly suitable for brittle materials with high stress distribution requirements.
Implementation Method 1
The respective component is built up layer by layer from a supply of powder by melting the powder
Implementation Method 2
This leads to local solidification of the respective melted layer
Implementation Method 3
at least one cooling air hole is formed in the respective slot-like recess
Data Source
Figure 1~3
Figure 4~5
Figure 6
AI summary
The invention relates to a plate-shaped component of a gas turbine with a base body (1) which is integrally provided at at least one edge region with an edge strip (2) formed substantially perpendicular to the surface of the base body (1), wherein the base body (1) has a different thickness (d1) than the edge strip (2), characterized in that a support body (3) is arranged integrally with the base body (1) and the edge strip (2), having a substantially triangular cross-section, and which is provided with several slot-like recesses (4).