Turbine Airfoil Trailing-Edge Cooling With Nested Channels
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Solution Overview
Problem
High-efficiency combustion turbines face challenges in maintaining uniform temperature and extending the lifespan of turbine airfoils due to intense heat and pressure, where existing cooling methods are hindered by the materials and conformations of turbine components, particularly at the trailing edge.
Innovation Solution
The implementation of nested cooling channels along the trailing edge of turbine airfoils, formed by metal three-dimensional printing, which are fluidly isolated and can have various geometries such as wavy, zigzag, or serpentine designs, allowing for efficient passage of cooling fluid from the interior to the exterior and compensating for any blockages by neighboring channels.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If conventional cooling channels are used in turbine airfoils, then the cooling fluid can flow through the component, but the temperature distribution remains non-uniform and cooling efficacy is inhibited by material and conformation constraints
Solution Approach 1:
The patent implements nested cooling channels where one cooling channel is positioned within another cooling channel, allowing multiple cooling paths through the same spatial region. This nested configuration enables more uniform temperature distribution across the turbine airfoil while maintaining effective cooling, as the multiple channels work synergistically to address thermal gradients that single channels cannot resolve
2Temperature
If the turbine airfoil uses CMC materials for high temperature resistance, then heat resistance improves, but cooling fluid passage and heat dissipation become more difficult
Solution Approach 1:
The cooling system is segmented into multiple independent nested channels rather than a single passage. This segmentation allows the cooling fluid to distribute more effectively through the CMC material structure, overcoming the difficulty of heat dissipation in ceramic matrix composites while maintaining the material's high temperature resistance properties
3Device complexity
If a single cooling channel is used, then the structure is simple, but blockages cannot be compensated and cooling coverage is limited
Solution Approach 1:
Multiple cooling channels are nested within each other, creating a compact multi-channel system that maintains relatively simple overall structure while providing redundancy. If one channel becomes blocked, the nested channels continue to provide cooling pathways, thereby improving cooling reliability without requiring a complex distributed channel network
Solution Approach 2:
The nested channel configuration provides built-in redundancy that cushions against potential blockages before they compromise cooling effectiveness. The presence of multiple nested channels ensures that cooling functionality is maintained even if individual channels become obstructed, providing fault tolerance inherent in the design
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 ensures a more uniform temperature distribution and enhances the lifespan of turbine airfoils by effectively cooling the trailing edge, even in high-temperature environments, by allowing cooling fluid to flow through multiple channels and maintaining operational efficiency.
Implementation Method 1
flowing a fluid through a manifold inserted into the core of the nozzle or blade, which exits the manifold through impingement holes into a post-impingement cavity
Implementation Method 2
cooling the trailing edge of a turbine airfoil... maintaining a substantially uniform temperature of a turbine airfoil
Data Source
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AI summary
A turbine component (10) includes a root (11) and an airfoil (12) extending from the root (11) to a tip (14) opposite the root (11). The airfoil (12) forms a leading edge (15) and a trailing edge portion (42) extending to a trailing edge (16). A plurality of nested cooling channels (40) in the trailing edge portion (42) of the airfoil (12) permit passage of a cooling fluid from an interior of the turbine component (10) to an exterior of the turbine component (10) at the trailing edge portion (42). A method of making a turbine component (10) includes forming an airfoil (12) having a leading edge (15), a trailing edge portion (42) extending to a trailing edge (16), and a plurality of nested cooling channels (40) in the trailing edge portion (42). Each nested cooling channel fluidly connects an interior of the turbine component (10) with an exterior of the turbine component (10) at the trailing edge portion (42). A method of cooling a turbine component (10) is also disclosed.