Interlocking Airfoil Endwall Segments for Thermal Management
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Solution Overview
Problem
Gas turbine engines face inefficiencies due to the need for compressor bleed cooling, which compromises engine efficiency, and the challenge of managing thermal resistance in high-temperature components, particularly in the turbine section.
Innovation Solution
The design incorporates airfoils with ceramic or ceramic matrix composite leading ends and metal trailing ends, along with interlocking endwall sections and tension members, to enhance thermal resistance and reduce the need for compressor bleed cooling, while allowing for adjustable airfoil profiles to optimize pressure ratios and fuel efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If compressor bleed cooling is used to manage thermal resistance in high-temperature components, then thermal resistance is managed, but engine efficiency decreases
Solution Approach 1:
The patent changes the material parameter of the airfoil from traditional metal to ceramic or ceramic matrix composite, which fundamentally alters the thermal properties. This material parameter change enables the airfoil to withstand high temperatures without requiring compressor bleed cooling, thus maintaining engine efficiency while managing thermal resistance
Solution Approach 2:
The patent employs composite materials, specifically ceramic matrix composites (CMC), that combine the high-temperature resistance of ceramics with the toughness and damage tolerance of composite structures. This composite approach allows the airfoil to operate in high-temperature environments without requiring energy-intensive cooling systems
2Adaptability or versatility
If airfoil pieces are secured between endwall sections with interlocking mechanisms, then assembly flexibility and material optimization are improved, but device complexity increases
Solution Approach 1:
The airfoil is segmented into multiple pieces that can be separately manufactured from different materials (ceramic for leading end, metal for trailing end) and then assembled between endwall sections. This segmentation enables material optimization for different functional regions while maintaining assembly flexibility through standardized interfaces
Solution Approach 2:
The endwall sections with interlocking mechanisms serve multiple functions: they provide structural support, enable assembly/disassembly flexibility, accommodate different airfoil piece configurations, and facilitate maintenance. This multi-functionality reduces the need for separate specialized components
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 improves thermal resistance, reduces compressor bleed requirements, and enhances overall engine efficiency by tailoring pressure ratios, leading to better thrust-specific fuel consumption and operational capabilities.
Implementation Method 1
The design incorporates airfoils with ceramic or ceramic matrix composite leading ends and metal trailing ends, along with interlocking endwall sections and tension members, to enhance thermal resistance
Data Source
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AI summary
An airfoil (60) includes an airfoil section (66) that defines an airfoil profile (AP), and a first endwall section (62; 162) with which the airfoil section (66) is attached. First and second airfoil pieces (68, 70) form different portions of the airfoil profile (AP). The first and second airfoil pieces (68, 70) include respective first ends (72, 74). The first ends (72, 74) interlock with the first endwall section (62; 162) such that the first and second airfoil pieces (68, 70) are retained with the first endwall section (62; 162).