Trailing-Edge Cooling Hole Profiles for Turbine Airfoil Longevity
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Solution Overview
Problem
Aerodynamic turbomachine components in the hot gas flow path of a gas turbine engine experience thermal strain leading to creep and reduced useful life, necessitating improved cooling strategies.
Innovation Solution
A method involving a digital model simulation and iterative adjustment of cooling hole profiles in aerodynamic components, using artificial intelligence for optimization, to enhance thermal management and reduce strain.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional cooling strategies are employed in aerodynamic turbomachine components, then thermal strain is reduced to some extent, but further reductions are difficult to achieve and component life is still limited
Solution Approach 1:
The invention applies different cooling strategies to different regions of the turbine blade. Specifically, it provides for a first cooling strategy for a first region of the turbine blade and a second cooling strategy for a second region of the turbine blade. This localized approach allows optimization of cooling effectiveness in specific high-thermal-strain areas without compromising overall blade performance, thereby extending component life while maintaining adaptability.
Solution Approach 2:
The turbine blade is divided into multiple regions with distinct cooling strategies. The cooling system is segmented into different functional zones, each tailored to the thermal and mechanical demands of that specific region. This segmentation enables more precise thermal management and allows for greater overall cooling effectiveness compared to a uniform cooling approach.
2Reliability
If cooling apertures and structures are added to reduce thermal strain, then component life increases, but device complexity increases
Solution Approach 1:
The cooling structures are integrated within the turbine blade geometry in a nested manner. Cooling apertures, passages, and channels are incorporated into the blade structure itself, with cooling features embedded within the blade body and trailing edge structures. This nesting approach reduces overall device complexity by combining cooling functionality with the structural geometry rather than adding separate cooling components.
Solution Approach 2:
The cooling system is merged with the turbine blade structure. Cooling apertures in the trailing edge and internal cooling passages are integrated into the blade design, combining the structural and cooling functions into a single unified component. This merging reduces the number of separate parts and simplifies the overall device while maintaining effective cooling.
3Manufacturing precision
If iterative digital model simulation and AI optimization are used to optimize cooling hole profiles, then manufacturing precision is improved, but productivity decreases due to extended development time
Solution Approach 1:
Digital model simulation and AI optimization are performed during the design and development phase, before actual manufacturing. The iterative optimization of cooling hole profiles and exit passage geometries is conducted virtually using computational models, allowing precise optimization to be achieved without extending physical prototyping and testing cycles. This preliminary action ensures manufacturing precision is established before production begins.
Solution Approach 2:
Physical trial-and-error prototyping is replaced with digital model simulation and AI-based optimization. The mechanical process of building and testing multiple physical prototypes is substituted with computational modeling, numerical simulation, and algorithmic optimization. This substitution maintains high manufacturing precision while significantly reducing development time and improving productivity.
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
Significant reduction in thermal strain, increasing creep life by 26% to 30% and overall component life by a factor of 4, through optimized cooling hole profiles.
Implementation Method 1
A cooling circuit (146) is provided in the aerodynamic component (100). The cooling circuit includes a cooling passage (150) defined in a body (134) of the aerodynamic component (100).
Implementation Method 2
The cooling circuit includes an exit passage (150) and a cooling hole (144) at a trailing edge (142) of the aerodynamic component (100).
Data Source
AI summary
A gas turbine airfoil includes a trailing edge cooling hole that has an elliptical cross-sectional baseline shape. In addition, the exit passage wall leading to the trailing edge cooling hole has a surface that varies according to an exit passage profile. Applying an iterative method of embodiments can produce a final exit passage profile with significantly reduced thermal strain during operation as compared to the prior art, resulting in improved component life.