Solid Capillary Airfoil With Machined Thermal Passages

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Solution Overview

Problem

Hollow vanes used for thermal management in engines fail to meet dimensional and material requirements due to limitations in casting processes, leading to metallurgical and supplier unwillingness to meet engine operating conditions.

Innovation Solution

A process of forming a capillary airfoil design with a solid body, incorporating airflow passages and a cover to create a monolithic airfoil assembly, allowing for active heating and cooling by machining internal passages and attaching a cover to form a desired vane geometry.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If hollow vanes are manufactured by casting with internal cores, then the thermal management function is achieved, but the dimensional precision and material quality requirements cannot be met

Engineering Contradiction:

Improvedimensional precisionVSAvoidmanufacturing complexity

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The airfoil is divided into two separate components: a solid airfoil body and a cover. The solid body is machined with precise internal passages for thermal management, while the cover is separately formed and then attached to enclose the passages. This segmentation allows each component to be manufactured with optimal precision and quality control, resolving the contradiction between dimensional precision and manufacturing complexity.

Inventive Principle:

Principle #1Segmentation

2Reliability

If casting process is used for hollow vanes, then the thermal management capability is provided, but the supplier willingness and process capability to meet engine operating conditions are insufficient

Engineering Contradiction:

Improvematerial qualityVSAvoidprocess capability

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

Instead of casting hollow vanes with internal cores (traditional approach), the invention inverts the approach by first machining a solid airfoil body with precise internal passages, then enclosing it with a separately formed cover. This inversion allows the use of machining processes that provide superior dimensional precision and material quality control, meeting engine operating conditions while maintaining manufacturing feasibility.

Inventive Principle:

Principle #13The other way round (Inversion)

3Manufacturing precision

If a solid airfoil body with internal passages is machined, then the geometric precision is improved, but the manufacturing complexity increases

Engineering Contradiction:

Improvegeometric precisionVSAvoidmanufacturing steps

Core Design Contradiction:

Manufacturing precisionVSDevice complexity

Solution Approach 1:

The manufacturing process is segmented into distinct steps: machining the solid airfoil body with internal passages, separately forming the cover, and then assembling them. This segmentation of the manufacturing process allows each step to be optimized independently, achieving high geometric precision in the machined body while managing overall manufacturing complexity through systematic division of tasks.

Inventive Principle:

Principle #1Segmentation

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 capillary airfoil design meets geometric requirements, enables active air cooling/heating, solves structural and airflow issues, and allows for direct machining access and low-cost inspections, optimizing ice protection and airflow.

Implementation Method 1

forming a major airflow passage in the solid airfoil body within the faceplate cavity, the major airflow passage being in fluid communication with the inlet port; forming a minor airflow passage within the solid airfoil body within the faceplate cavity, the minor airflow passage being in fluid communication with the major airflow passage

Methodology Applied

Scientific EffectFluid flow:

Implementation Method 2

forming a cover, the cover being configured to attach to the faceplate cavity to enclose each of the major airflow passage and the minor airflow passage

Methodology Applied

Scientific EffectPhysical containment: Physical Containment

Data Source

PatentEP4613974A1Process of forming a capillary airfoil design for active heating and cooling, and solid airfoil

Publication Date: 2025.09.10 RTX CORP

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AI summary

A solid airfoil assembly (60) comprises: - a solid airfoil body (62) including a leading edge (70) and a trailing edge (72), a suction side (74) opposite a pressure side (72), a first trunnion (78) proximate the leading edge opposite a second trunnion (80) proximate the leading edge; - a faceplate cavity (88) formed within the solid airfoil body; - an inlet port (82) formed through the first trunnion; - a major airflow passage (90) formed within the faceplate cavity, the major airflow passage being in fluid communication with the inlet port; - a minor airflow passage (92) formed within the solid airfoil body within the faceplate cavity, the minor airflow passage being in fluid communication with the major airflow passage; - an exit port (94) in fluid communication with the minor airflow passage, the exit port being in fluid communication with the inlet port; and - a cover (64) attached to the faceplate cavity enclosing each of the major airflow passage and the minor airflow passage.