Segmented Ceramic Coating for Airfoil Thermal Protection
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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, and there is a need to enhance temperature resistance of components exposed to high temperatures.
Innovation Solution
A geometrically segmented ceramic coating with a laminar microstructure is applied to airfoils, filling polygonal cells on the suction side, providing thermal resistance and reducing internal stresses, thereby minimizing the need for compressor bleed cooling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If compressor bleed cooling is used to cool components exposed to high temperatures, then temperature resistance is improved, but engine efficiency deteriorates due to pressure differential penalties
Solution Approach 1:
The patent replaces the mechanical/compressor-based cooling system with a thermal barrier coating system. Instead of using compressor bleed air to actively cool components, a ceramic coating is applied to the airfoil to provide passive thermal protection, eliminating the need for energy-intensive compressor bleed cooling.
Solution Approach 2:
The ceramic coating acts as an intermediary layer between the high-temperature environment and the airfoil substrate. This coating layer absorbs and blocks thermal energy, protecting the underlying metal structure from direct thermal exposure without requiring active cooling systems.
2Temperature
If a continuous coating is applied to the airfoil, then temperature resistance is improved, but internal stresses increase leading to coating failure
Solution Approach 1:
The patent divides the continuous coating into discrete geometric segments or cells separated by gaps. This segmentation allows the coating to expand and contract independently in each segment, accommodating thermal expansion differences between the ceramic coating and metal substrate without generating excessive internal stresses that would cause delamination or cracking.
Solution Approach 2:
The coating is applied with different properties in different locations - the geometric segments provide thermal protection where needed, while the gaps between segments provide stress relief. This local variation in coating continuity allows simultaneous optimization of both thermal resistance and stress management.
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
The coating enhances temperature resistance, reducing the need for compressor bleed cooling and improving engine efficiency by maintaining component integrity at high temperatures.
Implementation Method 1
A geometrically segmented coating section is provided on an airfoil section... The coating enhances temperature resistance... providing thermal resistance
Implementation Method 2
A geometrically segmented coating section is provided on an airfoil section... reducing internal stresses... The cells are polygonal
Data Source
Figure 1~2C
Figure 3A~5
Figure 6~7
AI summary
An airfoil includes an airfoil body that has a geometrically segmented coating section (70). The geometrically segmented coating section (70) includes a wall (72) having an outer side (72b). The outer side (72b) has an array of cells (74), and there is a coating (80) disposed in the array of cells (74).