Turbine Abradable Layer with Multi-Level Ridge Arrays

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

Turbine engines face challenges in maintaining efficient operation due to blade tip wear and leakage, which are exacerbated by manufacturing tolerances, thermal distortion, and operational variations, leading to compromised efficiency and potential engine damage.

Innovation Solution

The development of abradable components with distinct forward and aft composite multi-orientation groove and ridge patterns that redirect and block blade tip airflow leakage, featuring vertically projecting ridges with progressive wear zones to minimize wear and maintain narrow blade tip gaps, while also facilitating easier abradability and thermal resistance.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If a single abradable surface design is used, then manufacturing and installation are simplified, but it cannot simultaneously optimize performance for both standard and fast start modes

Engineering Contradiction:

Improveoperational mode adaptabilityVSAvoidabradable surface design complexity

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The abradable surface is segmented into multiple functional zones with distinct ridge patterns. The first plurality of ridges has a first pattern optimized for standard operation, while the second plurality of ridges has a second pattern optimized for fast start mode. This segmentation allows each zone to perform its specific function while collectively providing multi-mode adaptability.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Different regions of the abradable surface are given different local qualities through varied ridge configurations. The first ridge plurality features specific spacing and geometry for standard mode performance, while the second ridge plurality has different spacing and geometry for fast start mode performance. Each local region is optimized for its intended operational condition.

Inventive Principle:

Principle #3Local quality

2Loss of energy

If blade tip gap is reduced to improve efficiency, then energy loss decreases, but blade tip wear and potential contact with abradable surface increases

Engineering Contradiction:

Improveblade tip leakageVSAvoidblade tip wear resistance

Core Design Contradiction:

Loss of energyVSReliability

Solution Approach 1:

The abradable surface ridges are positioned and configured in advance to create a protective barrier before blade tip contact occurs. The ridge patterns are designed to redirect airflow and prevent direct blade-tip-to-abradable-surface contact, thereby protecting the blade tip from wear while maintaining reduced gap efficiency.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The abradable surface ridges act as an intermediary element between the blade tip and the underlying surface. Instead of direct contact between the blade tip and the abradable surface material, the ridges intermediate this interaction, redirecting airflow and distributing contact forces to prevent localized wear while maintaining the benefits of reduced tip gap.

Inventive Principle:

Principle #24Intermediary (Mediator)

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 effectively reduces blade tip leakage and wear, enhances engine efficiency, and allows for a single design to operate in both standard and fast start modes, maintaining aerodynamic control and thermal integrity.

Implementation Method 1

abradable components with distinct forward and aft composite multi-orientation groove and ridge patterns that redirect and block blade tip airflow leakage

Methodology Applied

Scientific EffectFlow redirection:

Implementation Method 2

vertically projecting ridges with progressive wear zones to minimize wear

Methodology Applied

Scientific EffectAbrasion: Abrasion

Implementation Method 3

maintain narrow blade tip gaps, while also facilitating easier abradability and thermal resistance

Methodology Applied

Scientific EffectThermal resistance: Thermal Insulation

Data Source

PatentUS9151175B2Turbine abradable layer with progressive wear zone multi level ridge arrays

Publication Date: 2015.10.06 SIEMENS ENERGY GLOBAL GMBH & CO KG

AI summary

Turbine and compressor casing abradable component embodiments for turbine engines, with composite grooves and vertically projecting alternating rows of first and second height ridges in planform patterns, to reduce, redirect and/or block blade tip airflow leakage downstream into the grooves rather than from turbine blade airfoil high to low pressure sides. The first ridges have a first ridge height greater than that of the second ridges. These ridge or rib embodiments have first lower and second upper wear zones. The lower zone, at and below the second ridge height, optimizes engine airflow characteristics, while the upper zone, between tips of the second and first ridges, is optimized to minimize blade tip gap and wear by being more easily abradable than the lower zone.