Segmented Turbine Coating with Internal Cooling Passage
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Solution Overview
Problem
Gas turbine engines face inefficiencies due to the need for compressor bleed cooling, which compromises engine efficiency 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 coating section with ceramic material is applied to gas turbine components, featuring an array of cells with a cooling passage, where the coating is deposited and then partially removed to open the passage, reducing the need for compressor bleed and enhancing thermal resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If compressor bleed cooling is used to cool turbine components, then temperature resistance of components is improved, but engine efficiency deteriorates due to pressure differential requirements
Solution Approach 1:
The invention extracts the cooling function from the compressor bleed system and relocates it to a dedicated cooling passage within the turbine component. This allows the cooling function to be separated from the compressor operation, eliminating the need to divert high-pressure air from the compressor for cooling purposes.
Solution Approach 2:
The invention introduces a cooling passage as an intermediary structure that enables thermal management of turbine components without relying on compressor bleed. The cooling passage acts as a mediator between the turbine component and the cooling medium, providing an alternative thermal management pathway that does not compromise engine efficiency.
2Temperature
If a coating is deposited on the turbine component wall, then temperature resistance is improved, but the cooling passage becomes blocked
Solution Approach 1:
The invention applies preliminary action by depositing the protective coating on the wall before the cooling passage is opened. The coating is applied to the encapsulated cooling passage, and subsequent removal of the encapsulation exposes the cooling passage while retaining the coating on the wall, ensuring the coating is in place before the passage is accessed.
Solution Approach 2:
The invention segments the cooling passage structure by using an encapsulation that can be selectively removed. This segmentation allows the cooling passage to be isolated during coating deposition, then opened afterward to provide access for cooling while maintaining the coating integrity on the surrounding wall structure.
3Productivity
If the encapsulation is removed to open the cooling passage, then cooling functionality is improved, but coating material is lost
Solution Approach 1:
The invention applies local quality by selectively removing the encapsulation only in the specific region where cooling passage access is required, while preserving the coating material on the surrounding wall. This localized removal approach ensures that coating material is not unnecessarily lost while still providing the necessary cooling functionality.
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 reduces the requirement for compressor bleed cooling, thereby increasing engine efficiency by enhancing the temperature resistance of components, particularly at the compressor exit and turbine inlet.
Implementation Method 1
depositing a coating on a wall. The wall includes a first side and a second side opposite the first side
Data Source
Figure 1~3
Figure 4~6D
AI summary
A gas turbine engine component includes a passage (68) and a geometrically segmented coating section adjacent the passage (68). The geometrically segmented coating section includes a wall (72) that has a first side (72a) bordering the passage (68) and a second side (72b) opposite the first side (72a). The second side (72b) includes an array of cells (74), and there is a coating (76) disposed over the array of cells (74). The coating (76) defines an exterior side (74). A cooling passage (78) extends through the wall (72) and the coating (76). The cooling passage (78) fluidly connects the passage (68) and the exterior side (76c).