Serpentine Airfoil Cooling with Flow Control Cavity
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Solution Overview
Problem
Existing gas turbine engine airfoil designs face challenges in efficiently providing cooling to the trailing edge region, particularly due to the weight increase and manufacturing complexities associated with thickened ribs used for resupply feeds, which can disrupt cooling air flow and reduce thermal cooling efficiency.
Innovation Solution
The design incorporates a serpentine cooling flow path with a flow control feature at the junction of resupply and serpentine cavities, including tapering core portions and ejection holes to manage airflow and prevent backflow, ensuring efficient cooling by directing serpentine cooling air and resupply air in a manner that enhances convective heat transfer.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If a thickened rib is used to angle resupply air away from the serpentine exit, then cooling coverage at the trailing edge is improved, but part weight increases and manufacturing complexity increases
Solution Approach 1:
The patent removes the thickened rib structure from the airfoil design and replaces it with a flow control cavity that uses airflow dynamics rather than structural bulk to achieve the same cooling air redirection function. This extraction of the heavy structural element resolves the weight increase problem while maintaining cooling effectiveness.
Solution Approach 2:
The patent changes the approach from structural modification (thickened rib) to flow control modification (flow control cavity with specific geometry). By altering the cavity geometry parameters and using airflow control mechanisms rather than increasing structural mass, the design achieves the same cooling air angle control without the weight penalty.
2Temperature
If a thickened rib is used to angle resupply air away from the serpentine exit, then cooling coverage at the trailing edge is improved, but manufacturing producibility deteriorates
Solution Approach 1:
The patent removes the complex thickened rib structure that is difficult to manufacture and replaces it with a flow control cavity that can be formed using standard manufacturing processes. This extraction of the hard-to-manufacture structural element resolves the manufacturing producibility problem.
Solution Approach 2:
The patent replaces the mechanical structural solution (thickened rib) with a flow control solution (flow control cavity utilizing airflow patterns). This substitution eliminates the need for complex structural manufacturing while achieving the same functional outcome of directing cooling air away from the serpentine exit.
3Temperature
If resupply air is supplied to the third serpentine cavity, then cooling efficiency is improved, but backflow into the second serpentine cavity may occur disrupting flow
Solution Approach 1:
The patent introduces a flow control cavity as an intermediary structure between the resupply cavity and the serpentine cavities. This intermediary flow control mechanism prevents direct backflow of resupply air into the second serpentine cavity while still allowing the resupply air to cool the third serpentine cavity, thus maintaining flow stability.
Solution Approach 2:
The patent extracts the potential backflow problem by separating the resupply air path from the second serpentine cavity through the flow control cavity intermediary. This extraction prevents the harmful backflow effect while preserving the beneficial cooling effect in the third serpentine cavity.
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 improves cooling efficiency at the trailing edge by optimizing airflow, reducing back pressure, and increasing the internal convective heat transfer, thereby enhancing the durability and thermal performance of gas turbine engine airfoils.
Implementation Method 1
enabling a cooling flow in a first direction within the airfoil body... enabling a cooling flow in a second direction... enabling a cooling flow in at least one of the first direction or a third direction
Implementation Method 2
a flow control feature located at the junction and arranged to at least one of (i) turn the serpentine cooling air from the second direction to at least one of the first or third direction
Implementation Method 3
arranged to at least one of (i) turn the serpentine cooling air from the second direction to at least one of the first or third direction or (ii) prevent the resupply air from flowing into the second serpentine cavity
Data Source
AI summary
Airfoils having a body with leading and trailing edges and a first serpentine cavity within the body enabling a cooling flow in a first direction within the airfoil body, a second serpentine cavity fluidly connected to the first serpentine cavity enabling a cooling flow in a second direction, and a third serpentine cavity fluidly connected to the second serpentine cavity enabling a cooling flow in at least one of the first direction or a third direction. A resupply cavity is fluidly connected to the third serpentine cavity to supply a resupply air to the third serpentine cavity, a junction at the location of the second serpentine cavity, the resupply cavity and the third serpentine cavity, and a flow control feature arranged to turn the serpentine cooling air from the second direction and/or prevent resupply air backflow.