Thermal Management Article with Grooved Ducts for Gas Turbine Cooling
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Solution Overview
Problem
Current methods for enhancing the temperature capability of gas turbine components, such as brazing or using sacrificial materials, face challenges like material sagging or costly leeching processes, which are not efficient for forming exterior covers over cooling channels.
Innovation Solution
A method involving a substrate with grooves and ducts that are brazed or welded to form a thermal management article, allowing fluid pathways for temperature alteration, using three-dimensional printing for duct geometry conformity and materials with high thermal conductivity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If thermal spraying is used directly over cooling channels, then coating material fills the cooling channel, but this blocks the fluid pathway and reduces cooling efficiency
Solution Approach 1:
The groove is formed in the substrate surface before applying the exterior cover, creating a pre-defined recess that prevents coating material from filling the cooling channel during thermal spraying or other coating processes
Solution Approach 2:
The exterior cover acts as an intermediary layer that protects the cooling channel while allowing thermal energy transfer, with the groove ensuring the cover does not obstruct the fluid pathway
2Strength
If brazing is used to attach exterior cover over cooling channels, then the cover is securely attached, but the high brazing temperature softens the cover material causing it to sag or droop into the cooling channels
Solution Approach 1:
The groove is pre-formed to contain the cover material during attachment, preventing sagging before it occurs
Solution Approach 2:
The groove geometry parameters (depth, width, shape) are optimized to accommodate the cover material at brazing temperature without allowing it to sag into the cooling channel, while still achieving secure attachment
3Reliability
If sacrificial material is used to fill cooling channels before coating, then the cooling channel is protected from coating material, but the filling and leeching processes become difficult and expensive
Solution Approach 1:
The groove is formed in advance to prevent coating material intrusion, eliminating the need for sacrificial materials and their associated filling and leeching processes
Solution Approach 2:
The problematic sacrificial material step is completely removed from the manufacturing process by using the groove structure instead
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 efficient temperature management, extends component life, reduces cooling flow requirements, and allows for adjustable temperature control, preventing thermal issues like fatigue and oxidation, while using less expensive materials and improving system efficiency.
Implementation Method 1
The at least one inner surface defines at least one fluid pathway through the at least one duct. The at least one duct and the at least one groove include features adapted to permit a fluid to enter the at least one duct from the substrate and exit the at least one duct to an exterior environment or to a pathway within the substrate.
Implementation Method 2
A method involving a substrate with grooves and ducts that are brazed or welded to form a thermal management article
Implementation Method 3
A method involving a substrate with grooves and ducts that are brazed or welded to form a thermal management article
Data Source
Figure 1~2
Figure 3
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AI summary
A thermal management article 401, a method for forming a thermal management article 401 and a method for thermal management of a substrate are disclosed. Forming a thermal management article 401 includes forming a duct 201 adapted to be inserted into a groove 103 on the surface 102 of a substrate 101, and attaching the duct 201 to the groove 103 so that the top outer surface 205 of the duct 201 is substantially flush with the surface 102 of the substrate 101. Thermal management of a substrate 101 includes transporting a fluid through the duct 201 of a thermal management article 401 to alter the temperature of the substrate 101.