Hot Gas Components with Compound Angled Cooling Features
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Solution Overview
Problem
Current film cooling strategies in gas turbine engines are inefficient and costly, leading to non-uniform temperature profiles and reduced aero-efficiency due to the use of shaped cooling holes, which are difficult to manufacture and result in low film effectiveness.
Innovation Solution
The implementation of compound angled cooling features in hot gas path components, including pairs of cooling supply outlets with complementary compound angles, enhances film cooling effectiveness by improving the attachment of coolant streams to the surface, reducing mixing, and simplifying manufacturing processes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If shaped cooling holes are used to improve film cooling effectiveness, then film effectiveness increases, but manufacturing complexity and cost increase
Solution Approach 1:
The patent changes the geometric parameters of the cooling holes by introducing compound angles (both axial and radial components) instead of using complex shaped holes. This parameter modification allows achieving improved film cooling effectiveness through angle optimization rather than through complex hole shaping, thereby reducing manufacturing complexity while maintaining or improving cooling performance
Solution Approach 2:
The patent adds a radial angle component to the traditional axial cooling hole configuration, creating a three-dimensional compound angle structure. This dimensional enhancement allows the cooling flow to better attach to the surface and follow the contour, improving film effectiveness without requiring complex hole shapes that are difficult to manufacture
2Temperature
If compressed air is released through small holes on the airfoil surface to form a cooling film, then cooling and insulation are achieved, but aero-efficiency decreases
Solution Approach 1:
The patent applies local quality by directing the cooling flow precisely where needed through compound angled holes that align with the surface contour. The cooling is concentrated at the leading edge and along the suction surface where thermal loads are highest, rather than distributing cooling uniformly, which reduces the total amount of cooling air required and minimizes aero-efficiency penalties
Solution Approach 2:
The patent uses partial action by providing cooling only in the regions of highest thermal demand (leading edge and suction surface) rather than cooling the entire airfoil surface. This selective cooling approach reduces the quantity of cooling air needed, thereby reducing the negative impact on aero-efficiency while still achieving adequate component cooling
3Reliability
If cooling fluid exits through cooling holes into the freestream passage, then film cooling is provided, but the cooling fluid separates from the wall surface resulting in low efficiency
Solution Approach 1:
The patent introduces a radial angle component in addition to the axial angle, creating a compound three-dimensional hole orientation. This radial component directs the cooling flow radially outward in alignment with the surface contour, enabling the cooling fluid to follow the airfoil surface into the adverse pressure gradient region and maintain attachment, preventing early separation and improving film cooling efficiency
Solution Approach 2:
The patent employs asymmetric compound angles where the axial and radial angle components are optimized independently based on the local surface geometry and flow conditions. This asymmetric configuration allows the cooling holes to be tailored to the specific requirements of different locations on the airfoil, improving flow attachment and cooling efficiency at each location
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 increases film effectiveness, reduces the amount of cooling required, enhances engine efficiency, and lowers manufacturing costs by using easier-to-produce cylindrical or round holes, while maintaining or improving cooling performance.
Implementation Method 1
the supply of air forms a thin layer or film of relatively cool air at the surface of the airfoil, which both cools and insulates the part from the higher temperatures that surround it. This type of cooling is commonly referred to as 'film cooling'.
Implementation Method 2
the supply of air forms a thin layer or film of relatively cool air at the surface of the airfoil, which both cools and insulates the part from the higher temperatures that surround it
Implementation Method 3
enhances film cooling effectiveness by improving the attachment of coolant streams to the surface
Implementation Method 4
enhances film cooling effectiveness by improving the attachment of coolant streams to the surface, reducing mixing
Data Source
AI summary
A hot gas path component including a substrate having an outer surface exposed to a stream of hot gases and an inner surface exposed to a cooling flow. One or more pair of cooling supply inlets is formed at the inner surface of the substrate for receiving the cooling air flow. One or more pair of cooling supply outlets is formed at the outer surface of the substrate for discharging the cooling air flow. A cooling flow channel extends through the substrate and between each of cooling supply inlets and the cooling supply outlets for permitting passage of the cooling air flow. Each pair of the one or more pair of cooling supply outlets is configured having complementary compound angles α and β, where α1 and α2 are injection angle components of the cooling flow discharged from each pair of the one or more pair of cooling supply outlets and β1 and β2 are compound transverse angle components of the cooling flow discharged from each pair of the one or more pair of cooling supply outlets, and wherein the transverse angle components β1 and β2 are of the same sign.