Additively Manufactured Impingement Sleeve with Support Pins
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Solution Overview
Problem
Existing impingement sleeves in gas turbine systems face challenges in controlling the impingement distance and directing cooling air to tight-to-reach spots on heated structures, such as narrow corners or sharp transitions, which limits their cooling efficiency.
Innovation Solution
The use of an additively manufactured impingement sleeve with a column of ports extending from its outer surface, each directing an impingement stream towards a heated structure, and pins disposed outside the cooling flow to support the ports during manufacturing, allowing for controlled impingement distance and improved air directionality.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional impingement sleeves are used, then cooling air can be routed through the sleeve, but the impingement distance cannot be precisely controlled and tight-to-reach spots cannot be effectively cooled
Solution Approach 1:
The patent changes the geometric parameters of the impingement sleeve by incorporating ports at specific angles (greater than 45 degrees relative to the build direction) and incorporating pins at specific orientations (within threshold angle of build direction). These parameter changes enable precise control of impingement distance while maintaining manufacturability through additive manufacturing processes.
Solution Approach 2:
The patent introduces a new dimension of control by adding pins that extend in the build direction, creating a three-dimensional structure that precisely positions the ports. This dimensional addition allows for controlled impingement distance and effective cooling of tight-to-reach spots that conventional two-dimensional port arrangements cannot achieve.
2Reliability
If ports are oriented at angles greater than 45 degrees relative to build direction, then cooling efficiency is improved, but additive manufacturing stability is compromised
Solution Approach 1:
The pins serve as intermediary structures that support the ports during additive manufacturing. By providing this intermediate support framework, the patent enables the creation of ports at angles greater than 45 degrees relative to the build direction, which would otherwise be unstable during the manufacturing process, while maintaining manufacturing feasibility.
Solution Approach 2:
The pins are incorporated into the additive manufacturing process as preliminary support structures before the final cooling geometry is complete. This preliminary action of adding support elements during manufacturing allows for stable construction of angled ports, which are then removed or integrated into the final structure, enabling high cooling efficiency without compromising manufacturing stability.
3Manufacturing precision
If pins are added to support ports during manufacturing, then manufacturing precision is improved, but device complexity increases
Solution Approach 1:
The patent merges the support function with the structural geometry by designing pins that are integrated into the impingement sleeve body. These pins serve dual purposes: providing necessary support during additive manufacturing and becoming part of the final structural design. This merging reduces device complexity compared to adding separate, removable support elements.
Solution Approach 2:
The pins are designed to be self-supporting structures that stabilize the ports during manufacturing without requiring external support systems or post-processing operations. The pins' geometry and orientation (within threshold angle of build direction) enable them to support themselves and the ports during the additive manufacturing process, eliminating the need for additional manufacturing infrastructure or complex assembly steps.
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 configuration enhances cooling efficiency by enabling precise control of cooling air impingement on heated structures, effectively cooling tight-to-reach areas and improving overall heat transfer through convection.
Implementation Method 1
each port of the column of ports is configured to direct an impingement stream toward a heated structure, and each impingement stream includes a portion of the cooling flow
Data Source
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AI summary
A system 10 having an impingement sleeve 92 configured to receive a cooling flow 81 is provided. The impingement sleeve 92 includes a column of ports 100 extending from an outer surface 98 of the impingement sleeve 92, wherein each port of the column of ports 100 is configured to direct an impingement stream 81 toward a heated structure 88, 108, and each impingement stream includes a portion of the cooling flow 81. Further, one or more pins 138 are disposed outside the outer surface 98 relative to the cooling flow 81, wherein each pin of the one or more pins 138 is coupled between pairs 101 of ports of the column of ports 100.