Impingement Cover Tabs for Gas Turbine Nozzle Welding
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Solution Overview
Problem
Existing methods for joining an impingement cover to a gas turbine engine nozzle rail often result in areas of negative reinforcement and potential cracking due to thermal expansion and minimal clearances, which can increase manufacturing costs and require separate tooling for stabilization.
Innovation Solution
The use of multiple tabs extending from the edges of the impingement cover, which act as stand-offs to create a space between the cover and the nozzle rail, preventing negative reinforcement and allowing for a stable joint formation through welding, thereby preventing cracks and reducing manufacturing complexities.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If minimal clearances are used when joining the impingement cover to the nozzle rail, then the joint size is reduced, but areas of negative reinforcement and potential cracking occur due to thermal expansion
Solution Approach 1:
Tabs are attached to the impingement cover before the joining process to pre-establish spacing between the cover and nozzle rail. This preliminary action prevents negative reinforcement and cracking by ensuring adequate clearance is maintained throughout welding and thermal expansion, eliminating the need for separate stabilization tools.
Solution Approach 2:
Tabs serve as intermediary elements between the impingement cover and nozzle rail, creating a controlled space that accommodates thermal expansion. These tabs act as spacers that prevent direct contact while maintaining structural integrity, allowing the joint to withstand thermal stresses without cracking.
2Stability of the object's composition
If separate tooling is used for stabilization during joining, then joint stability is improved, but device complexity and manufacturing costs increase
Solution Approach 1:
The stabilization function is merged into the impingement cover itself through integrated tabs. Instead of using separate external tooling for stabilization, the tabs are permanently attached to the cover, combining the stabilization and structural functions into a single component, thereby reducing manufacturing complexity and eliminating the need for additional tools.
Solution Approach 2:
The impingement cover stabilizes itself during the joining process through its own integrated tabs. The tabs provide inherent stabilization without requiring external fixtures or separate tooling, allowing the component to serve its own stabilization needs and simplifying the manufacturing process.
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
The tab-based design stabilizes the impingement cover during joining, prevents cracks, and minimizes manufacturing costs by ensuring a secure and reliable joint without the need for additional stabilization tools, enhancing the structural integrity of the gas turbine engine nozzle assembly.
Implementation Method 1
areas of negative reinforcement and potential cracking due to thermal expansion
Implementation Method 2
allowing for a stable joint formation through welding
Data Source
AI summary
An impingement cover (460) for fusing to a gas turbine engine turbine nozzle (451) with a nozzle rail (455) includes a body and a plurality of tabs for forming a first fuse with the nozzle rail (455). The body has a plate like shape and includes a plurality of impingement holes (464), a first edge, a second edge, and a first airfoil cooling hole (470). The plurality of tabs includes a first tab (461) extending from the first edge, and a second tab (462) extending from the second edge. The second tab (462) is located in a different quadrant of the body than the first tab (461).