Integral Turbine Casing Cooling Ducts for Thermal Stress Reduction
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Solution Overview
Problem
Gas turbine engines face increased manufacturing costs and weight due to complex external piping systems for cooling and clearance control, which are not efficiently addressing temperature and stress management in turbine casings.
Innovation Solution
The integration of an internal cooling duct system within the turbine casing, featuring apertures for direct cooling fluid flow to critical regions, reduces thermal gradients and stress, and allows for additive manufacturing to create lighter, more efficient components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If external piping systems are used for cooling the turbine casing, then the casing temperature can be controlled, but the device complexity and weight increase
Solution Approach 1:
The cooling ducts are integrated directly into the turbine casing structure, merging the cooling system with the casing itself. This eliminates the need for separate external piping systems while maintaining effective cooling of the casing, thereby reducing device complexity and weight.
Solution Approach 2:
The patent introduces cooling air as an intermediary substance that flows through integrated ducts within the casing to transfer heat away from critical regions. This mediator approach allows temperature control without complex external mechanical systems.
2Temperature
If external piping systems are used for cooling the turbine casing, then the casing temperature can be controlled, but the engine weight increases
Solution Approach 1:
By integrating the cooling ducts into the casing structure itself, the patent eliminates redundant external piping components. This consolidation reduces the overall weight of the engine while maintaining effective temperature control of the turbine casing.
Solution Approach 2:
The cooling ducts are strategically positioned to target specific high-temperature regions within the casing. This localized cooling approach uses minimal cooling air and structural material, reducing overall weight while effectively managing temperature where it is most critical.
3Reliability
If thick and reinforced housing walls are used to contain broken blades, then safety is improved, but manufacturing costs and weight increase
Solution Approach 1:
The integrated cooling ducts create localized reinforced zones within the casing wall where cooling channels are present. These zones provide both structural strength for blade containment and thermal management, eliminating the need for uniformly thick walls throughout the entire housing.
Solution Approach 2:
The casing structure incorporates integrated cooling channels that create a composite-like structure with varying wall thicknesses. The regions with cooling ducts provide enhanced strength and thermal resistance, allowing thinner walls in non-critical areas and reducing overall weight while maintaining safety.
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 solution enhances cooling effectiveness, improves clearance control, and reduces material costs by minimizing thermal stress and temperature, enabling the use of lighter materials and more complex designs through additive manufacturing.
Implementation Method 1
a first flow of cooling fluid from the cooling air source is directed through the integral cooling duct within the turbine casing and through the first portion of the apertures directly to the first region where the turbine casing and the turbine shroud are connected
Data Source
AI summary
A turbine clearance control system is provided. The turbine clearance control system includes a cooling air source and a turbine casing surrounding a portion of a turbine, wherein the turbine casing defines an integral cooling duct within the turbine casing, the integral cooling duct including apertures on an interior surface of the turbine casing.