Segmented Rib Discharge Holes for Gas Turbine Cooling
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Solution Overview
Problem
In gas turbine engines, the cooling cavities within airfoil components often experience insufficient cooling due to specific flow characteristics, leading to hot spots and potential thermal mechanical fatigue (TMF) cracks, exacerbated by dead zones created by segmented ribs which disrupt flow and reduce convective heat transfer.
Innovation Solution
The introduction of discharge holes at the segment gaps between segmented ribs in airfoil components, utilizing advanced additive manufacturing and fugitive core technologies to ensure precise placement, enhances cooling by extracting cooling air from these cavities and eliminating dead zones, thereby improving heat transfer and reducing TMF risks.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If segmented ribs are used to separate cooling cavities, then structural support and cavity separation are improved, but dead zones are created that disrupt flow and reduce convective heat transfer
Solution Approach 1:
The ribs are segmented into multiple rib segments separated by segment gaps, allowing cooling air to pass through and eliminating dead zones while maintaining structural support functionality
Solution Approach 2:
Segment gaps act as intermediaries between cooling cavities, allowing cooling air to flow through the rib structure and connect previously isolated cooling zones, thereby eliminating hot spots
2Temperature
If segmented ribs with segment gaps are introduced, then convective heat transfer is improved by eliminating dead zones, but device complexity increases
Solution Approach 1:
Multiple rib segments are combined to form a complete rib structure that provides both structural support and flow passage functionality, reducing the need for separate components
Solution Approach 2:
The segmented rib structure serves multiple functions simultaneously: structural support, flow separation, and flow passage through segment gaps, eliminating the need for additional dedicated flow passage components
3Temperature
If discharge holes are added at segment gaps, then cooling air extraction and dead zone elimination are improved, but manufacturing complexity increases
Solution Approach 1:
Fugitive cores are placed in the mold cavity before casting to pre-establish the precise locations of discharge holes and segment gaps, ensuring accurate positioning without requiring complex post-processing
Solution Approach 2:
Fugitive cores serve as temporary intermediaries during manufacturing, occupying the space where discharge holes and segment gaps will ultimately exist, and are removed after casting to reveal the precise features
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 effectively increases convective cooling, reduces thermal mechanical fatigue, and enhances the durability of airfoil components by eliminating hot zones and improving flow dynamics within the cooling cavities.
Implementation Method 1
a discharge hole formed in the external side wall fluidly connected the segment gap to an exterior surface of the component body
Data Source
AI summary
Components for gas turbine engines and methods of making the same, the components including a component body having an external side wall and an internal side wall and defining at least a first cooling cavity and a second cooling cavity between the external side wall and the internal side wall, at least one segmented rib extending within the component body and separating the first cooling cavity from the second cooling cavity, wherein the first and second cooling cavities, the at least one segmented rib comprising at least two rib segments separated by a segment gap, and a discharge hole formed in the external side wall fluidly connected the segment gap to an exterior surface of the component body.