Refractory Metal Core for Gas Turbine Cooling Circuits
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Solution Overview
Problem
Gas turbine engine components, such as turbine blades and vanes, face challenges in managing high thermal loads due to their exposure to extreme temperatures, necessitating effective cooling systems that are not adequately addressed by existing technologies.
Innovation Solution
A refractory metal core with a trunk and multiple branches is used to create a cooling circuit within gas turbine engine components, allowing for cooling air to be discharged at multiple locations on the component's exterior, enhancing convective and conductive heat transfer through the integration of air disturbance features and various attachment methods like welding or gluing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If cooling circuits are placed just under the surface of the airfoil through which cooling air flows, then cooling efficiency is improved, but manufacturing complexity increases
Solution Approach 1:
The refractory metal core is divided into multiple separate bodies (first refractory metal core body, second refractory metal core body, etc.) that are attached to different cavity core structures. Each core body can be manufactured independently and then assembled together, simplifying the manufacturing process while maintaining the complex cooling circuit configuration needed for high cooling efficiency.
Solution Approach 2:
The refractory metal core bodies are nested within and attached to cavity core structures during the casting process. The cooling circuits are formed within the refractory metal core bodies, which are then positioned within the component cavity, creating a nested arrangement that simplifies manufacturing while achieving the desired cooling efficiency.
2Reliability
If multiple cooling circuit portions are provided to cool different surfaces, then heat management is improved, but device complexity increases
Solution Approach 1:
The cooling system is segmented into multiple independent refractory metal core bodies, each responsible for cooling specific surfaces or regions of the component. This segmentation allows each core body to be optimized for its specific cooling function while maintaining overall system manageability.
Solution Approach 2:
Each refractory metal core body serves multiple functions: it defines cooling passages, provides structural support, and enables cooling at multiple locations. The trunk portion serves as both a structural element and a common attachment point for multiple cooling circuit branches, reducing overall system complexity.
3Area of stationary object
If the trunk includes a stack of multiple refractory metal core bodies, then cooling coverage is improved, but manufacturing precision requirements increase
Solution Approach 1:
The refractory metal core is segmented into multiple bodies that can be manufactured separately with standard tolerances, then assembled using attachment methods (welding, gluing, mechanical attachment). This segmentation reduces the manufacturing precision requirements compared to producing a single monolithic core with all cooling passages and precise alignment features.
Solution Approach 2:
Multiple refractory metal core bodies are merged into a stack configuration through attachment methods to form the complete trunk structure. This merging approach allows each individual core body to be manufactured with standard precision, while the assembly process achieves the overall precision required for multi-surface cooling coverage.
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 configuration improves heat management by providing efficient cooling on multiple surfaces, reducing the complexity of cooling systems and extending product life while maintaining operational efficiency.
Implementation Method 1
cooling air to be discharged at multiple locations on the component's exterior, enhancing convective and conductive heat transfer
Implementation Method 2
cooling air to be discharged at multiple locations on the component's exterior, enhancing convective and conductive heat transfer
Data Source
Figure 1A
Figure 1B
Figure 2A
AI summary
Refractory metal cores (338a-e; 438) for manufacturing components of gas turbine engines (20), manufactured components, and related methods are provided. A refractory metal core includes a trunk (350a-e; 450) configured to attach to a cavity core structure (232; 234; 236), a first branch (356a-e; 456a) extending from the trunk and configured to form a first portion of a cooling circuit (528; 628; 728a; 728c) in the component, and a second branch (356a-e; 456b) extending from the trunk and configured to form a second portion of the cooling circuit in the component. The first branch and the second branch are configured to define fluid exits at two different locations on an exterior of the component.