Mixed Cooling Nub Feature for Gas Turbine Heat Transfer
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Solution Overview
Problem
Gas turbine engine components face challenges in efficiently managing heat due to uniform cooling nub configurations, which limit heat transfer and are constrained by casting techniques, particularly near edges and acute angles, where ideal-sized nubs cannot be positioned, leading to reduced cooling effectiveness.
Innovation Solution
A mixed cooling nub feature with non-uniform distances and distinct geometries, including multiple cross-sectional shapes and configurations, is integrated into the component as a single cast element, allowing for increased surface area exposure and localized cooling by distributing nubs unevenly and using smaller nubs near edges and acute angles.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If uniform cooling nub configurations are used, then manufacturing is simplified, but heat transfer efficiency is limited
Solution Approach 1:
The patent applies local quality by varying the cooling nub geometries (different heights, diameters, and spacing) at different locations on the component surface. This allows each region to have optimized cooling characteristics tailored to local heat generation and flow conditions, improving overall heat transfer efficiency while remaining manufacturable through investment casting techniques.
Solution Approach 2:
The patent implements asymmetry by using non-uniform cooling nub configurations where nubs have different dimensions and spacing patterns rather than repeating identical geometries. This asymmetric arrangement optimizes convective cooling by creating varied flow paths and enhancing turbulence in regions that benefit most from increased heat transfer.
2Reliability
If ideal-sized cooling nubs are positioned near edges and acute angles, then cooling effectiveness is improved, but casting constraints prevent proper placement
Solution Approach 1:
The patent applies parameter changes by systematically varying the cooling nub dimensions (height, diameter, spacing) based on location. Near edges and acute angles where casting constraints exist, smaller nub parameters are used that can be properly formed by investment casting, while still providing effective cooling. This allows ideal cooling performance to be achieved within manufacturing capabilities.
3Reliability
If surface area exposure is increased, then convective cooling is enhanced, but component complexity increases
Solution Approach 1:
The patent applies segmentation by dividing the cooling surface into multiple discrete cooling nub features rather than using a single continuous cooling structure. This segmentation increases the effective surface area exposed to coolant flow, enhancing convective cooling. The segmented nubs can be integrated into the component during investment casting, managing complexity through process selection.
Solution Approach 2:
The patent merges the cooling features directly into the component body through investment casting, creating an integrated structure where cooling nubs are formed as part of the base component geometry. This combining approach increases surface area for cooling while avoiding the complexity of separate attached cooling components, as the entire structure is cast as one piece.
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 approach enhances convective cooling by increasing the surface area exposed to the coolant flow, improving heat transfer and addressing the limitations of traditional casting methods, thereby extending component life and performance.
Implementation Method 1
The cooling flow continuously cycles a coolant, such as air, over one or more surface of the component. The cycling of the coolant removes the warmed coolant and replaces the warmed coolant with a cooled coolant.
Implementation Method 2
In order to mitigate the effects of the high temperatures, some components are exposed to cooling flows and convective heat transfer from the component to the cooling flow cools the component.
Data Source
Figure 1
Figure 2~7C
AI summary
A component (100; 200) for a gas turbine engine (20) includes at least one cooled surface (110; 210; 310; 410) configured to contact a cooling flow (102; 202), the at least one cooled surface (110...410) has a base surface and a plurality of cooling nubs (122, 124; 222, 224; 324; 422, 424) disposed about the base surface. The plurality of cooling nubs (122...424) are distributed about the base surface in a mixed pattern.