Lined Turbine Cooling Apertures With Meter-Diffuser Alignment

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Solution Overview

Problem

Existing methods for forming cooling apertures in gas turbine engine components are not optimized for efficient fluid flow and thermal management, leading to suboptimal performance and potential misalignment issues between meter and diffuser sections.

Innovation Solution

A manufacturing method involving a preform component with a substrate, internal and external coatings, where the meter section is formed in the substrate and the diffuser section is created in both the substrate and external coating, using techniques like electrical discharge machining and laser machining, with potential alignment correction using imaging systems and predictive modeling.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If traditional cooling aperture formation methods are used, then manufacturing process is simpler, but alignment precision between meter and diffuser sections deteriorates

Engineering Contradiction:

Improvealignment precisionVSAvoidmanufacturing process complexity

Core Design Contradiction:

Manufacturing precisionVSDevice complexity

Solution Approach 1:

The meter section is formed in the substrate before applying the external coating, establishing a precise reference structure in advance. This preliminary formation of the meter section allows subsequent diffuser section machining to align accurately to it, ensuring precise alignment while managing process complexity through staged manufacturing

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The cooling aperture is divided into distinct meter section and diffuser section that are formed in separate stages. The meter section is formed in the substrate first, then the external coating is applied, and finally the diffuser section is machined. This segmentation allows each section to be optimized and aligned independently, improving overall alignment precision

Inventive Principle:

Principle #1Segmentation

2Productivity

If cooling aperture geometry is not optimized, then manufacturing process is simpler, but fluid flow efficiency deteriorates

Engineering Contradiction:

Improvefluid flow efficiencyVSAvoidmanufacturing complexity

Core Design Contradiction:

ProductivityVSEase of manufacture

Solution Approach 1:

The cooling aperture geometry is optimized with specific local features including a meter section with controlled dimensions for flow regulation and a diffuser section with expanded geometry for flow distribution. The diffuser section may include multi-lobed configurations or varying cross-sectional areas to enhance fluid flow efficiency and thermal management at critical locations

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The cooling aperture geometry is designed to dynamically adapt fluid flow characteristics along its length. The meter section provides flow metering and control, while the diffuser section progressively expands to distribute flow, creating a dynamic flow management system that optimizes cooling efficiency throughout the component

Inventive Principle:

Principle #15Dynamics

3Temperature

If thermal management is not optimized, then component design is simpler, but thermal management performance deteriorates

Engineering Contradiction:

Improvethermal management performanceVSAvoidcoating structure complexity

Core Design Contradiction:

TemperatureVSDevice complexity

Solution Approach 1:

The component employs a composite structure with a metal substrate and a ceramic-based external coating (such as thermal barrier coating). This composite material system provides enhanced thermal management performance by combining the mechanical properties of metal with the thermal insulation properties of ceramic, allowing the component to withstand high temperatures while maintaining structural integrity

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

Inventive Principle:

Principle #3Local quality

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 method enhances the formation of cooling apertures by improving fluid flow regulation and thermal management, ensuring precise alignment between meter and diffuser sections, thereby increasing the efficiency and reliability of gas turbine engine components.

Implementation Method 1

The meter section may be formed using an electrical discharge machining process

Methodology Applied

Scientific EffectElectrical discharge machining: Electrical Discharge Machining

Implementation Method 2

The diffuser section may be formed using a laser machining process

Methodology Applied

Scientific EffectLaser machining: Laser Ablation

Data Source

PatentUS11913358B2Forming lined cooling aperture(s) in a turbine engine component

Publication Date: 2024.02.27 RTX CORP

AI summary

A manufacturing method is provided. During this method, a preform component is provided for a turbine engine. The preform component includes a substrate. A meter section of a cooling aperture is formed in the substrate. An internal coating is applied onto a surface of the meter section. An external coating is applied over the substrate. A diffuser section of the cooling aperture is formed in the external coating and the substrate to provide the cooling aperture.