Segmented Ceramic Thermal Barrier Coating for Gas Turbine Vanes
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Solution Overview
Problem
Gas turbine engines face efficiency challenges due to the need for compressor bleed cooling, which penalizes engine performance by relying on pressure differential, making it difficult to reduce compressor bleed volume, increase velocity, or raise temperature while maintaining high pressure and low temperature requirements.
Innovation Solution
The development of a vane with a geometrically segmented ceramic thermal barrier coating and a core skeleton that includes internal passages and cooling holes, reducing the need for compressor bleed by enhancing temperature resistance, particularly at the compressor exit and turbine inlet, using a ceramic matrix composite or monolithic ceramic materials.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If compressor bleed cooling is used to cool the turbine, then the turbine can operate at high temperatures, but the engine efficiency is reduced due to the pressure differential requirement and the volume of bleed air needed
Solution Approach 1:
The patent changes the thermal properties of the vane by applying a geometrically segmented ceramic thermal barrier coating, which increases the temperature resistance of the vane material. This allows the vane to withstand higher turbine inlet temperatures without requiring as much compressor bleed cooling, thereby reducing the energy loss associated with bleed air extraction.
Solution Approach 2:
The patent uses a composite structure combining a metal core skeleton with a ceramic thermal barrier coating. The ceramic material (such as yttria-stabilized zirconia) provides superior thermal insulation properties compared to the metal core, creating a composite vane that can operate at higher temperatures while reducing the cooling air requirement and improving overall engine efficiency.
2Loss of energy
If the vane material temperature resistance is increased, then the need for compressor bleed cooling is reduced, but the device complexity increases due to the geometrically segmented ceramic coating structure
Solution Approach 1:
The thermal barrier coating is applied in a geometrically segmented manner rather than as a continuous coating. This segmentation allows for better stress distribution, improved thermal management, and easier application of the ceramic material. The segmented structure reduces the complexity of manufacturing compared to a solid ceramic vane while still achieving the goal of reducing compressor bleed volume.
Solution Approach 2:
The geometrically segmented coating provides different thermal protection levels in different regions of the vane, optimizing the thermal barrier properties where they are most needed. This local quality approach allows the vane to achieve adequate temperature resistance with a less complex overall structure compared to a uniformly thick ceramic coating.
3Reliability
If higher temperature bleed air is used for cooling, then the cooling effectiveness is improved, but the temperature resistance requirements of the vane material increase
Solution Approach 1:
The composite vane structure with ceramic thermal barrier coating enables the use of higher temperature bleed air for cooling. The ceramic material protects the metal core skeleton from the high temperatures of the bleed air and the turbine environment, allowing the system to utilize hotter cooling air that provides better cooling effectiveness without compromising the structural integrity of the vane.
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 enhances temperature resistance, potentially reducing the need for compressor bleed and enabling the use of higher temperature bleed air, thereby improving engine efficiency and reducing efficiency penalties.
Implementation Method 1
a geometrically segmented ceramic thermal barrier coating
Implementation Method 2
core skeleton that includes internal passages and cooling holes
Data Source
Figure 1~9
Figure 2~5
Figure 6
AI summary
An airfoil includes an airfoil section that defines an airfoil profile. The airfoil section includes a distinct panel that forms a portion of the airfoil profile. The panel has a geometrically segmented coating section (72). The geometrically segmented coating section (72) includes a wall (74) that has an outer side (74b). The outer side (74b) includes an array of cells (76), and there is a coating (80) disposed in the array of cells (76). Corresponding gas turbine engine comprising said airfoil is also provided.