Porous Gas Turbine Wall Segment Cooling
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Solution Overview
Problem
The existing manufacturing processes for gas turbine engine components, such as turbine shrouds and heat shields, require a high number of holes for cooling, leading to complex and lengthy processes, and there is a need for weight reduction in aircraft parts.
Innovation Solution
A metal-injection molded cooled wall segment is developed, incorporating a denser impermeable portion for retention and a porous permeable portion for cooling air circulation, allowing efficient heat management and reduced material usage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If a plurality of holes are provided for cooling air circulation, then cooling efficiency is improved, but device complexity and manufacturing time increase
Solution Approach 1:
The patent applies porous materials to create a porous portion within the wall segment that allows cooling air to circulate through the component. This porous structure replaces the need for multiple discrete holes, as the porous matrix itself provides numerous interconnected pathways for air flow. The porous portion is formed by specific manufacturing parameters (such as binder content and sintering conditions) that create controlled porosity while maintaining structural integrity. This approach achieves effective cooling surface area without the manufacturing complexity of drilling or forming numerous individual holes.
2Temperature
If a plurality of holes are provided for cooling, then cooling efficiency is improved, but manufacturing time increases
Solution Approach 1:
The patent merges the formation of multiple cooling holes into a single integrated porous structure formed during the metal injection molding process. Instead of creating numerous separate holes through multiple drilling or machining operations, the porous portion is formed in one step by controlling the injection molding parameters and subsequent sintering process. This consolidation of multiple hole-forming operations into a single process step dramatically reduces manufacturing time while maintaining the cooling functionality.
3Strength
If more material is used for structural integrity, then strength is improved, but weight increases
Solution Approach 1:
The patent applies local quality by creating distinct regions within the wall segment with different material densities and properties. The denser portion provides high strength and structural integrity where mechanical loads are applied, while the porous portion provides cooling functionality with reduced material content and lower weight. This spatial variation in material properties allows each region to be optimized for its specific function - the denser portion for structural support and the porous portion for thermal management - achieving overall weight reduction without compromising where strength is critical.
4Temperature
If porous portion is added for cooling, then cooling efficiency is improved, but manufacturing complexity increases
Solution Approach 1:
The patent achieves multi-functionality by integrating multiple features into a single molded component. The wall segment simultaneously provides structural support, cooling air circulation pathways, and weight reduction all in one piece formed by metal injection molding. The porous portion is not an add-on feature requiring separate manufacturing steps but is inherently created during the injection molding and sintering process through controlled material formulation and processing parameters. This universal approach eliminates the need for post-processing operations to create cooling channels or porous structures.
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 design enhances cooling efficiency while simplifying manufacturing and reducing weight, achieving effective heat dissipation and structural integrity with fewer holes and lighter materials.
Implementation Method 1
The porous portion is made of porous material and is permeable to air to define a fluid communication allowing the cooling air to reach the contact surface(s)
Data Source
Figure 1
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Figure 3A
AI summary
A component (20) including a porous portion (50a) which may be permeable or impermeable to air. The component is a cooled wall segment for a gas turbine engine, including a body defining a contact surface (24) configured to be in contact with circulating hot gas and an outer surface (32) configured to be in contact with cooling air. The body includes a first portion (52a) with at least one retention element, and a porous second portion (50a) made of a porous material permeable to air, containing a plurality of interconnected pores, and having a porosity greater than that of the first portion (52a). The second portion (50a) is engaged to the first portion (52a), defines at least part of the contact surface (24), and defines at least part of a fluid communication between the outer surface (32) and the contact surface (24) through the interconnected pores. The wall segment may be for example a heat shield or shroud segment.