Gas Turbine Cooling Apertures with Preform Contour Compensation
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current film cooling systems in gas turbine engines face challenges in achieving uniform coating distribution and efficiency due to non-homogeneous coating application methods, leading to sub-threshold material thicknesses and reduced cooling effectiveness, especially as future engines operate at higher temperatures.
Innovation Solution
A preform structure with differently contoured cooling apertures is designed to compensate for non-uniform coating application, ensuring that all apertures have the same slope profiles after coating, using techniques like additive manufacturing and directional coating methods to optimize coating distribution and retention.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional coating application methods are used, then coating process simplicity is maintained, but coating uniformity deteriorates leading to sub-threshold material thicknesses
Solution Approach 1:
The preform structure is designed with differently contoured cooling apertures before coating application to anticipate and compensate for non-uniform coating distribution. This preliminary geometric adjustment ensures that after coating, all apertures achieve uniform slope profiles and adequate material thickness, resolving the contradiction between coating uniformity and process complexity.
2Manufacturing precision
If uniform coating is achieved through directional coating methods, then coating precision is improved, but manufacturing complexity increases
Solution Approach 1:
The preform structure incorporates locally varied aperture contours tailored to specific coating deposition patterns. Each aperture's geometry is customized based on its location and expected coating distribution, allowing conventional coating methods to produce uniform results without requiring complex directional coating processes.
3Reliability
If cooling apertures are designed with standard geometry, then manufacturing simplicity is maintained, but cooling effectiveness deteriorates due to non-uniform coating
Solution Approach 1:
The cooling aperture geometries are pre-designed with compensatory features that counteract the anticipated non-uniform coating effects. By incorporating geometric variations in the preform stage, the system preemptively neutralizes the harmful effects of non-uniform coating, ensuring uniform post-coating aperture slopes and maintaining reliable cooling performance.
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 approach enhances cooling effectiveness by maintaining desired coating characteristics across the component, improving flow reductions and downstream film persistence, leading to more efficient engine operation and potential increased power output.
Implementation Method 1
using techniques like additive manufacturing and directional coating methods to optimize coating distribution and retention
Implementation Method 2
using techniques like additive manufacturing and directional coating methods to optimize coating distribution and retention
Data Source
AI summary
A method of forming a gas turbine engine component, the method including forming a plurality of cooling apertures in a preform structure of the component, the plurality of cooling apertures of the preform structure comprising a first cooling aperture and a second cooling aperture, wherein cross-sectional shapes of the first and second cooling apertures of the preform structure are different from one another, as measured in a same relative plane; and applying a coating to at least a portion of the preform structure to form the component, wherein a cross-sectional shape of the first and second cooling apertures of the component are approximately the same as one another, as measured in the same relative plane.