Gas Turbine Casing Additive Manufacturing Thermal Control
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Solution Overview
Problem
Gas turbine engine casings face issues with excessive deformation and thermal expansion, leading to performance loss and operability problems due to the need for separable flanges and additional weight, which also hinder effective thermal control and engine efficiency.
Innovation Solution
The development of an improved gas turbine engine with integral, unitary structures formed through additive manufacturing, featuring a clearance control system that includes thermal control rings and manifolds for efficient heat transfer and reduced weight, eliminating the need for flanges and sub-assemblies, and allowing for improved positioning of thermal control structures.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If separable flanges and assembled casing portions are used to limit deformation, then reliability is improved, but weight increases
Solution Approach 1:
The patent merges multiple casing portions into a single integral, unitary structure formed by additive manufacturing. This eliminates the need for separable flanges and assembled portions, reducing weight while maintaining the ability to limit deformation through the monolithic design. The integral structure removes unnecessary joints and connection hardware that contribute to weight.
Solution Approach 2:
The patent changes the manufacturing parameter from traditional subtractive or assembly-based methods to additive manufacturing. This enables the creation of complex integral structures with optimized geometry that can control deformation while minimizing material usage and weight. The additive process allows for internal lattice structures and optimized wall thicknesses that maintain strength with reduced weight.
2Adaptability or versatility
If separable flanges and assembled components are used, then adaptability is improved, but device complexity increases
Solution Approach 1:
The patent combines multiple separate components (casing portions, flanges, brackets, hangers) into a single integral structure. This reduces device complexity by eliminating the need for multiple parts and their associated assembly procedures, while the additive manufacturing process enables built-in adaptability through optimized geometric features and integration of mounting points.
Solution Approach 2:
The integral casing structure serves multiple functions simultaneously: it provides structural support, controls thermal deformation, integrates thermal control structures, and incorporates mounting features for turbine components. The additive manufacturing process enables the casing to perform these diverse functions within a single unified structure, reducing overall system complexity.
3Ease of manufacture
If traditional casing designs are used, then manufacturing ease is maintained, but thermal control effectiveness decreases
Solution Approach 1:
The patent changes the manufacturing parameter from traditional methods to additive manufacturing, which enables complex thermal control features that cannot be achieved with conventional processes. The additive process allows for internal channels, varying wall thicknesses, and integrated thermal control structures that optimize heat transfer while maintaining manufacturing efficiency through digital modeling and direct fabrication.
Solution Approach 2:
The patent applies local quality by varying the thermal properties and geometry of different regions within the integral casing. Additive manufacturing enables zone-specific optimization where wall thickness, material density, and internal structures are tailored to local thermal requirements. This allows for effective thermal control in critical areas while using minimal material elsewhere, improving overall thermal management effectiveness.
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 enhances engine efficiency, reduces weight, and improves thermal control by minimizing thermal gradients and deformation, thereby preventing undesired contact with turbine rotors and optimizing engine performance.
Implementation Method 1
manifolds for efficient heat transfer
Data Source
AI summary
A method of operating a gas turbine engine comprising: extracting a flow of air from a compressor section of the gas turbine engine into a first conduit; flowing the extracted flow of air through the first conduit to a first location at a turbine section of the turbine section, wherein a second conduit is in fluid communication with the turbine section at a second location; flowing a heat transfer fluid to a first heat exchanger positioned in thermal communication with the flow of air through the first conduit, the heat transfer fluid in thermal communication with the extracted flow of air through the first conduit via the first heat exchanger; and modulating, via a flow control device, a portion of the flow of air extracted from the first conduit to the second conduit downstream of the first heat exchanger.