Segmented Stator Vane Coating for Turbine Engines
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Solution Overview
Problem
The existing stator vane arrangements in turbine engines have blind spots during the coating process, leading to uneven thermal barrier layer application, increased thermal fatigue, and higher costs due to time and expense, which affects the durability and efficiency of the vane segments.
Innovation Solution
A stator vane arrangement with a first and second vane platform, where the stator vanes extend radially between the platforms and include apertures for secure fastening, utilizing a seal element to seal gaps and enhance coating uniformity, and incorporating a boot or seal ring for improved thermal protection and assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a line of sight coating process is used to apply thermal barrier layers to stator vane segments, then the coating process is simple and cost-effective, but blind spots are created that prevent even coating application
Solution Approach 1:
The stator vane arrangement is divided into multiple separable vane segments rather than a single integral component. Each segment can be independently coated, allowing the coating process to access all surfaces without creating blind spots. The segments are then assembled into the complete stator vane arrangement, maintaining structural integrity while enabling uniform coating application on all gas path surfaces.
Solution Approach 2:
The vane segments are coated with the thermal barrier layer before assembly into the complete stator vane arrangement. This preliminary coating action allows the coating process to access all surfaces of each segment independently, ensuring even coating application without the blind spots that would occur if the entire assembly were coated as a single unit.
2Strength
If vane airfoils and platform segments are formed integral as a unitary body, then structural strength is improved, but blind spots are created during coating that increase time and expense
Solution Approach 1:
The stator vane arrangement is segmented into multiple separable components (vane segments) that can be independently coated. This segmentation eliminates blind spots during the coating process, reducing coating time and expense while maintaining structural integrity through proper design of the segment interfaces and fastening mechanisms.
Solution Approach 2:
The vane segments are coated with the thermal barrier layer before assembly into the complete stator vane arrangement. This preliminary coating action allows all surfaces to be accessed and coated evenly, significantly reducing the time and expense associated with coating integral structures that would create blind spots.
3Ease of manufacture
If vane airfoils and platform segments are formed integral, then manufacturing is simplified, but thermal fatigue increases due to uneven coating
Solution Approach 1:
The stator vane arrangement is divided into multiple separable vane segments that can be independently coated with the thermal barrier layer. This segmentation ensures even coating application on all gas path surfaces, eliminating the thermal fatigue issues caused by uneven coating on integral structures, while the segments are assembled to maintain structural integrity.
4Device complexity
If a unitary body construction is used for vane segments, then assembly is simplified, but coating blind spots increase thermal fatigue and expense
Solution Approach 1:
The stator vane arrangement consists of multiple separable vane segments rather than a single unitary body. Each segment can be independently coated without creating blind spots, reducing coating expense and improving thermal fatigue resistance. The segments are designed with standardized interfaces and fastening mechanisms that simplify the assembly process, offsetting the increased number of components.
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 solution ensures even thermal barrier layer application, reduces thermal fatigue, and enhances the durability and efficiency of the stator vane arrangement by eliminating blind spots and improving the mechanical fastening and sealing of the vane segments.
Implementation Method 1
A thermal barrier layer may partially insulate the vane arrangement segment material from relatively hot core gas that flows through the turbine section during engine operation.
Implementation Method 2
An oxidation coating may primarily increase oxidation and corrosion resistance of the parent alloy material.
Data Source
AI summary
A stator vane arrangement for a turbine engine includes a first vane platform, a second vane platform and a plurality of stator vanes extending radially between the first and the second vane platforms. The first and the second vane platforms extend circumferentially around an axis, and the first vane platform includes an aperture. The stator vanes are arranged circumferentially around the axis, and include a first stator vane that extends radially into the aperture and is fastened to the first vane platform.