Modular Gas Turbine Vane Coating Pocket Design
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Solution Overview
Problem
Current gas turbine engine vane and blade assemblies are manufactured as single, integral pieces to prevent thermal barrier coating spallation, which limits the ability to tailor cooling technologies to different temperature conditions and complicates manufacturing and reconditioning processes.
Innovation Solution
A modular component design for gas turbine assemblies, where each component, such as inner and outer platforms and airfoils, has a coating pocket for thermal barrier coating application, allowing separate manufacturing and assembly without risking coating damage during assembly, enabling varied coating thicknesses and improved cooling technologies based on operating conditions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If vane and blade assemblies are manufactured as a single, integral piece, then the thermal barrier coating is protected from spallation during assembly, but the manufacturing complexity increases and the ability to tailor cooling technologies to different temperature conditions is reduced
Solution Approach 1:
The vane assembly is divided into multiple modular components (airfoil, inner platform, outer platform) that can be manufactured separately and assembled. Each component has its own coating pocket that protects the thermal barrier coating during assembly, eliminating the need to manufacture the entire assembly as a single integral piece while maintaining coating integrity.
2Reliability
If vane and blade assemblies are manufactured as a single, integral piece, then the thermal barrier coating is protected from spallation during thermal expansion and contraction, but the manufacturing processes become more complex
Solution Approach 1:
The assembly is segmented into separate components, each with individual coating pockets that protect the thermal barrier coating during assembly and thermal cycling. This allows simpler manufacturing processes for each component while maintaining coating protection through the modular design.
Solution Approach 2:
The coating pocket acts as an intermediary structure that protects the thermal barrier coating during assembly and thermal expansion/contraction. The pocket provides a protective cavity that prevents direct contact and potential damage to the coating while allowing for thermal movement.
3Adaptability or versatility
If components are manufactured separately and coated individually, then cooling technologies can be tailored to different operating conditions, but the risk of coating spallation during assembly increases
Solution Approach 1:
Each component (airfoil, inner platform, outer platform) is manufactured and coated separately with customized cooling technologies appropriate for its specific operating conditions. The coating pocket on each component protects its individual thermal barrier coating during assembly, enabling both customization and coating stability.
Solution Approach 2:
The coating pocket serves as a protective intermediary that allows individually coated components to be assembled without risking coating spallation. The pocket structure accommodates the coating on each component while preventing damage during the assembly process.
4Reliability
If the entire assembly is coated with thermal barrier coating, then comprehensive protection is achieved, but the manufacturing and reconditioning processes become more complex
Solution Approach 1:
The assembly is segmented into modular components, each with its own coating pocket and thermal barrier coating. This allows individual components to be removed, reconditioned, or replaced independently without affecting the entire assembly, significantly simplifying maintenance and repair operations while maintaining overall protection.
Data Source
AI summary
Modular assemblies for gas turbine engines such as modular vane assemblies and methods of manufacturing the same. The modular assembly includes a first modular component such as a vane platform having a first mating pocket, and a second modular such as an airfoil. The second modular component includes circumferentially extending first and second surfaces at first and second distal ends thereof, respectively, with the first surface being received within the first pocket when the modular assembly is in the assembled state. The second modular component also includes a coating pocket extending from the first surface to the second surface. The coating pocket is recessed towards an interior of the second modular component with respect to first surface and the second surface, and a thermal barrier coating is included within the coating pocket and not included on the first surface or the surface.