Segmented Micro-Channel Turbine Shroud Cooling
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Solution Overview
Problem
Gas turbine engine turbine shrouds face degradation due to high temperatures, leading to premature failure and increased operational costs, as existing cooling systems are inefficient and require excessive cooling air.
Innovation Solution
The implementation of a turbine shroud system with multiple cooling channels and segmented exit features, where the channels are formed within the shroud body using electrical discharge machining, and a pre-sintered preform layer is brazed onto the hot gas flow path side to reduce blockage and enhance cooling efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If traditional cooling systems are used in turbine shrouds, then cooling function is provided, but excessive cooling air is required and efficiency is low
Solution Approach 1:
The cooling channel is divided into multiple segments with segmented exit features that distribute the cooling fluid flow more effectively across the hot gas path surface, reducing the total quantity of cooling air needed while maintaining cooling efficiency
Solution Approach 2:
The exit features are strategically positioned at specific locations within the cooling channel to optimize local cooling distribution, ensuring efficient heat transfer at critical areas while reducing overall cooling air consumption
2Reliability
If cooling channels are formed within the shroud body, then cooling efficiency is improved, but manufacturing complexity increases
Solution Approach 1:
Electrical discharge machining is used to form the cooling channels within the shroud body, replacing traditional mechanical drilling or machining methods to create complex internal passages with precision and reduced manufacturing complexity
Solution Approach 2:
The cooling channel geometry is designed and prepared in advance with segmented exit features that are formed through electrical discharge machining, allowing for precise placement and optimization of cooling fluid flow paths before assembly
3Productivity
If segmented exit features are added to reduce blockage, then channel flow is improved, but manufacturing steps increase
Solution Approach 1:
Electrical discharge machining is used to form the segmented exit features, allowing complex geometries with multiple openings and optimized flow paths to be created in a single manufacturing step without requiring additional assembly operations
Solution Approach 2:
The segmented exit features are integrated directly into the cooling channel structure as a unified component, combining the channel formation and exit feature creation into a single manufacturing process rather than requiring separate steps
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 reduces hot gas leaks, extends the service life of turbine components, and improves efficiency by utilizing less cooling air, thereby reducing operational costs and stress on hot gas path components.
Implementation Method 1
The first and second channels are configured to receive the cooling fluid from the cavity to cool the body
Implementation Method 2
the channels are formed within the shroud body using electrical discharge machining
Implementation Method 3
a pre-sintered preform layer is brazed onto the hot gas flow path side
Data Source
AI summary
A system includes a shroud segment for use in a turbine and includes a body having a leading and trailing edge, first and second side edge, and a pair of opposed lateral sides between the leading and trailing edges and the first and second side edges. A first lateral side interfaces with a cavity having a cooling fluid. A first channel includes a first and second end portion. A second channel includes a third end portion and a fourth end portion. The first and second channels receive the cooling fluid from the cavity to cool the body. The second end portion includes a first segmented channel with first metering feature and the third end portion includes a second segmented channel with second exit feature. The first and second exit features meter a flow of the cooling fluid within the first and second channels.