Lined Turbine Cooling Apertures With Aligned Meter and Diffuser Sections

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Solution Overview

Problem

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

Innovation Solution

A manufacturing method involving a preform substrate with meter and diffuser sections, where an internal aluminide coating lines the meter section, and a ceramic external coating is applied over a metal substrate, with the diffuser section formed using laser machining and aligned using imaging systems or AI/machine learning for precise geometry prediction and alignment.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If conventional cooling aperture formation methods are used, then manufacturing simplicity is maintained, but alignment precision and geometry accuracy between meter and diffuser sections deteriorate

Engineering Contradiction:

Improvealignment precision between meter and diffuser sectionsVSAvoidmanufacturing process complexity

Core Design Contradiction:

Manufacturing precisionVSDevice complexity

Solution Approach 1:

The meter section is formed and lined with internal coating before the external coating is applied. This preliminary action ensures that the meter section geometry is established with high precision before subsequent coating steps, preventing alignment issues that would arise if both sections were formed simultaneously or sequentially without pre-positioning.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The cooling aperture is divided into distinct meter section and diffuser section with clear geometric separation. The meter section is formed through the substrate with internal coating, while the diffuser section is formed through the external coating. This segmentation allows independent optimization and precise control of each section's geometry and alignment.

Inventive Principle:

Principle #1Segmentation

2Reliability

If conventional cooling aperture formation methods are used, then manufacturing cost is reduced, but cooling efficiency and thermal management performance deteriorate

Engineering Contradiction:

Improvecooling efficiency and thermal management performanceVSAvoidmanufacturing ease

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

Different sections of the cooling aperture are given different properties: the meter section has internal coating for precise flow control and durability, while the diffuser section is formed through the external coating for optimized flow distribution. This local differentiation of material properties and geometric characteristics enhances overall cooling efficiency while maintaining manufacturing feasibility.

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The cooling aperture structure utilizes composite construction with internal coating material in the meter section and external coating material in the diffuser section. This composite approach allows each section to be made from materials optimized for its specific functional requirements, improving thermal management performance while maintaining manufacturing practicality.

Inventive Principle:

Principle #40Composite materials

3Manufacturing precision

If meter and diffuser sections are formed independently without alignment control, then manufacturing flexibility is maintained, but geometry alignment and cooling performance deteriorate

Engineering Contradiction:

Improvegeometry alignment between sectionsVSAvoidmanufacturing cycle time

Core Design Contradiction:

Manufacturing precisionVSProductivity

Solution Approach 1:

The meter section is formed and positioned with precise alignment requirements established before the external coating is applied and the diffuser section is formed. This preliminary establishment of alignment references ensures that subsequent diffuser section formation can be precisely aligned without requiring complex real-time alignment control, maintaining productivity while achieving high geometric alignment accuracy.

Inventive Principle:

Principle #10Preliminary action

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 ensures precise alignment and efficient cooling by forming aligned meter and diffuser sections within the cooling apertures, enhancing the thermal management and performance of turbine engine components.

Implementation Method 1

An internal coating is applied onto a surface of the meter section

Methodology Applied

Scientific EffectDeposition: Deposition (physical)

Implementation Method 2

An external coating is applied over the substrate

Methodology Applied

Scientific EffectCoating: Coatings

Implementation Method 3

A diffuser section of the cooling aperture is formed in the external coating and the substrate

Methodology Applied

Scientific EffectLaser ablation: Laser Ablation

Data Source

PatentUS11603769B2Forming lined cooling aperture(s) in a turbine engine component

Publication Date: 2023.03.14 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.