Multi-Part Insert for Gas Turbine Cooling
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Solution Overview
Problem
Gas turbine engines face inefficiencies in cooling due to the excessive use of cooling air, which reduces engine performance, and existing inserts are limited in their ability to be placed within irregularly shaped cavities, necessitating the development of innovative cooling solutions that can effectively utilize cooling air and adapt to complex cavity geometries.
Innovation Solution
The use of multi-part inserts with hinge portions and resilient biasing mechanisms that can be assembled within irregularly shaped cavities, including those with twisted or distorted geometries, to enhance cooling efficiency by guiding and recycling cooling air through impingement holes and chambers, and the application of additive layer manufacturing for intricate features that support heat transfer and airflow.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If cooling air is extracted from the compressor to cool turbine components, then the turbine components can operate at higher temperatures, but the engine operating efficiency decreases
Solution Approach 1:
The patent changes the thermal parameters of the cooling system by introducing impingement cooling that directly impacts the inner surface of the shell, creating more effective heat transfer zones. This allows reduction of cooling air mass flow while maintaining component temperature control, thereby improving engine efficiency
Solution Approach 2:
The cooling system is segmented into multiple functional zones including impingement cooling zones, film cooling zones, and heat transfer augmentation zones. This segmentation allows optimized distribution of cooling air to different areas, improving overall cooling efficiency and reducing total cooling air requirements
2Temperature
If CMC material is used for turbine components, then the temperature capability increases and cooling air requirement decreases, but the manufacturing complexity increases
Solution Approach 1:
The CMC component is divided into a shell and separate inserts that can be manufactured independently using different processes (CMC for the shell, metal casting or additive manufacturing for inserts). This segmentation reduces manufacturing complexity by allowing each part to be optimized for its specific material and function
Solution Approach 2:
The patent uses composite construction combining CMC material for the outer shell with metal inserts for internal cooling features. This composite approach leverages the high-temperature capability of CMC while using metal materials that are easier to manufacture with complex cooling geometries
3Reliability
If sheet metal inserts are used for impingement cooling, then the cooling effectiveness increases, but the ability to fit irregularly shaped cavities is limited
Solution Approach 1:
The insert is divided into multiple segments or parts that can be assembled together to conform to irregular cavity shapes. This segmentation allows the cooling system to adapt to complex geometries while maintaining the impingement cooling effectiveness of metal inserts
Solution Approach 2:
The insert design incorporates local variations in geometry, thickness, and cooling feature distribution to match the specific thermal and structural requirements of different regions within the irregular cavity, optimizing cooling effectiveness for each local area
4Ease of manufacture
If laser sintering is used to manufacture CMC components, then the manufacturing capability improves, but the structural complexity is limited
Solution Approach 1:
The component is segmented into a laser-sintered CMC shell and separately manufactured inserts. This allows the shell to be produced by laser sintering with its inherent geometric capabilities, while the inserts provide the complex internal cooling structures that would be difficult to create with additive manufacturing alone
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 solution allows for improved heat transfer and more effective use of cooling air, increasing film cooling effectiveness and coverage while reducing the quantity of cooling air required, thus enhancing the overall efficiency and durability of gas turbine components.
Implementation Method 1
Internal convection and external films are the main methods of cooling the aerofoils
Implementation Method 2
The cooling air from the compressor that is used to cool the hot turbine components
Implementation Method 3
additional cooling of a hollow turbine engine component can be achieved by providing sheet metal inserts such as tubes or plates which provide impingement cooling by directing cooling air onto the inside walls of the hollow component
Data Source
Figure 1
Figure 2
Figure 3(A)~3(B)
AI summary
Described is a gas turbine engine component (100), comprising a shell having an internal cavity for receiving a multi-part insert; a multi-part insert located within the cavity, wherein the multi-part insert comprises multiple separate parts assembled in an abutting relation with one another within the cavity to provide the multi-part insert; wherein the assembled insert includes at least one retention part, the retention part engaging with a wall of the cavity and at least one other insert part so as to retain the assembled insert within the cavity.