Heat-Shielded Fluid Conduits With Shifted Insulation Gap
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Solution Overview
Problem
Existing additive manufacturing techniques for fluid conduits in gas turbine engines face challenges in maintaining effective heat shielding due to thermal connections between the conduit and the heat shield, which undermines the insulation.
Innovation Solution
A method involving the formation of fluid conduits inside a heat shield using additive manufacturing, where the conduit and heat shield are initially aligned to exceed the maximum build angle, and then shifted relative to each other to maintain an insulation gap, with supports extending through apertures in the heat shield to secure the conduit.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If supports are used to hold the fluid conduit during additive manufacturing, then the conduit can be supported during the build process, but the supports create a thermal connection between the conduit and heat shield that undermines heat shielding
Solution Approach 1:
The patent introduces a thermal barrier coating on the supports that acts as an intermediary layer, allowing the supports to fulfill their mechanical function of holding the conduit during manufacturing while simultaneously blocking thermal conduction to maintain heat shielding effectiveness
Solution Approach 2:
The patent changes the thermal parameter of the supports by applying a thermal barrier coating, transforming them from thermally conductive elements into thermally insulating elements, thus resolving the contradiction between mechanical support and thermal isolation
2Device complexity
If the fluid conduit is formed inside the heat shield using additive manufacturing, then integration is achieved, but maintaining an insulation gap while exceeding maximum build angles creates manufacturing challenges
Solution Approach 1:
The patent applies preliminary action by pre-coating the supports with thermal barrier material before the additive manufacturing process, and by pre-planning the support removal and conduit shifting operations to maintain the insulation gap while achieving complex geometries that exceed maximum build angles
3Stability of the object's composition
If the conduit is secured to the heat shield, then structural stability is achieved, but thermal connection is created that reduces heat shielding efficiency
Solution Approach 1:
The patent uses a thermal barrier coating as an intermediary layer between the conduit and heat shield, allowing mechanical attachment for structural stability while preventing thermal conduction to maintain heat shielding efficiency
Solution Approach 2:
The patent segments the thermal path by introducing a thermal barrier layer that divides the contact interface between conduit and heat shield, allowing mechanical connection while blocking thermal energy transfer
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 effectively maintains the insulation gap and prevents thermal connection between the fluid conduit and the heat shield, thereby enhancing the heat shielding efficiency and supporting the additive manufacturing process.
Implementation Method 1
an insulation gap defined between the fluid conduit and the heat shield
Data Source
AI summary
A method includes forming fluid conduit inside a heat shield in an additive manufacturing process, removing powder from an interior passage of the fluid conduit and from an insulation gap defined between the fluid conduit and the heat shield, separating the heat shield and fluid conduit from the build platform, and shifting the fluid conduit to a shifted position relative to the heat shield. The method includes securing the fluid conduit to the heat shield in the shifted position.