Interlocking Turbine Airfoil Assembly With Adaptive Cooling

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Solution Overview

Problem

The efficiency of gas turbine engines is limited by the material properties of the first stage vanes and blades, which restrict the inlet temperature of the hot gas stream, and investment casting restricts the formation of complex geometries and fine features necessary for effective cooling.

Innovation Solution

A hot gas path component assembly with interlocking features and fill material at the interface between components, allowing for adaptive cooling passages to open only when a discontinuity in the fill material occurs, enhancing cooling efficiency and structural integrity.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If investment casting is used to form turbine airfoils, then material properties and structural strength are improved, but geometrical complexity and fine features necessary for effective cooling are restricted

Engineering Contradiction:

Improvestructural strengthVSAvoidgeometrical complexity

Core Design Contradiction:

StrengthVSShape

Solution Approach 1:

The turbine airfoil is divided into multiple separate components (body portion and second portion) that are manufactured independently using investment casting, then joined together through interlocking features. This segmentation allows each component to be optimized for strength while the assembly achieves complex geometries that would be impossible in a single casting.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The airfoil assembly combines multiple materials including superalloy components with fill material in the interlocking interface. This composite approach allows each material to be selected for its specific properties while the combination achieves both strength and geometric complexity.

Inventive Principle:

Principle #40Composite materials

2Productivity

If higher inlet temperature gas stream is passed through the turbine, then efficiency is improved, but material properties of first stage vanes and blades are exceeded

Engineering Contradiction:

ImproveefficiencyVSAvoidinlet temperature

Core Design Contradiction:

ProductivityVSTemperature

Solution Approach 1:

The airfoil is segmented into multiple portions with integrated cooling passages that allow cooling air to be routed through the structure. This segmentation enables effective cooling of the first stage airfoils, permitting higher inlet temperatures without exceeding material property limits.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Cooling air acts as an intermediary substance that is passed through cooling passages within the airfoil structure. This cooling air protects the airfoil surfaces from the hot gas stream, allowing the airfoil to withstand temperatures that would otherwise exceed material properties.

Inventive Principle:

Principle #24Intermediary (Mediator)

3Temperature

If cooling air is discharged through film cooling holes, then cooling efficiency is improved, but structural integrity at the interface between components may be compromised

Engineering Contradiction:

Improvecooling efficiencyVSAvoidstructural integrity

Core Design Contradiction:

TemperatureVSStrength

Solution Approach 1:

Interlocking features with fill material are incorporated into the component design before assembly. This preliminary preparation ensures that when components are joined, the interface has sufficient strength to maintain structural integrity while still allowing cooling passages to function effectively.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The interface between components uses a composite of fill material and mechanical interlocking features. This composite structure provides both the strength needed for structural integrity and the pathways needed for cooling air flow through film cooling holes.

Inventive Principle:

Principle #40Composite materials

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 increases the cooling efficiency and structural strength of turbine airfoils by allowing adaptive cooling and improved geometrical features, addressing the limitations of investment casting and material constraints.

Implementation Method 1

The cooling fluid flows into the interface between the first structure and the second structure portion only if there is a discontinuity in the fill material

Methodology Applied

Scientific EffectAdaptive cooling: Convection

Implementation Method 2

a second component portion which includes a second set of interlocking features mechanically coupled to the first set of interlocking features

Methodology Applied

Scientific EffectMechanical interlocking: Friction

Data Source

PatentUS11634990B2Component with mechanical locking features incorporating adaptive cooling and method of making

Publication Date: 2023.04.25 GE INFRASTRUCTURE TECH LLC

AI summary

A hot gas path component assembly includes a first component portion that includes a first set of interlocking features and a second component portion that includes a second set of interlocking features mechanically coupled to the first set of interlocking features. A fill material is disposed at an interface between at least one surface of the first set of interlocking features and at least one surface of the second set of interlocking features. The fill material is disposed during a joining process. The second component portion is joined to the first component portion via both the fill material and the first and second sets of interlocking features.