Turbine Cooling Apertures Adapted to Outer Coating Variation
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Solution Overview
Problem
Existing methods for forming cooling apertures in gas turbine engine components are not optimized, as they do not effectively account for variations in the outer coating characteristics, leading to potential inefficiencies in cooling fluid flow and thermal management.
Innovation Solution
A manufacturing method that involves determining the characteristics of the outer coating using AI, machine learning, or imaging systems, and adapting the design specifications for the cooling apertures, including the diffuser and meter sections, to ensure precise formation based on the coating thickness, geometry, and spatial orientation, allowing for revised machining instructions to optimize aperture dimensions and geometry.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional cooling aperture formation methods are used, then manufacturing simplicity is maintained, but cooling efficiency and thermal management are suboptimal due to inability to account for outer coating variations
Solution Approach 1:
The patent measures outer coating characteristics (thickness, topology) before forming cooling apertures, and uses this information to pre-adjust machining instructions. This preliminary characterization allows the manufacturing process to adapt to coating variations, optimizing cooling aperture geometry for thermal management efficiency without requiring complex real-time adjustments during machining.
Solution Approach 2:
The patent implements a dynamic manufacturing approach where cooling aperture formation parameters are adjusted based on measured outer coating characteristics. The machining instructions are modified in real-time or near-real-time based on actual coating conditions, allowing the process to adapt to variations in coating thickness and topology, thereby optimizing cooling efficiency for each specific component.
2Productivity
If cooling aperture design specifications are adapted based on outer coating characteristics, then cooling fluid flow efficiency is improved, but measurement and characterization requirements increase
Solution Approach 1:
The patent establishes a feedback loop where outer coating characteristics are measured, and this measurement information feeds back into adjusting cooling aperture formation parameters. The measured coating thickness and topology data are used to modify machining instructions, creating a closed-loop system that continuously optimizes cooling aperture geometry based on actual coating conditions, thereby improving cooling fluid flow efficiency.
Solution Approach 2:
The patent replaces traditional mechanical measurement methods with advanced imaging systems and artificial intelligence for characterizing outer coating characteristics. These non-contact, automated measurement systems can accurately determine coating thickness and topology without physical contact, reducing measurement difficulty and enabling precise adaptation of cooling aperture design specifications.
3Measurement precision
If AI and machine learning are used to determine outer coating characteristics, then measurement precision is improved, but system complexity and computational requirements increase
Solution Approach 1:
The patent introduces imaging systems as an intermediary between the outer coating and the manufacturing control system. These imaging systems capture detailed images of coating characteristics, and AI algorithms process these images to extract precise measurements of coating thickness and topology. This intermediary approach enables high-precision measurement while keeping the manufacturing system adaptable and modular.
Data Source
AI summary
A manufacturing method is provided during which a preform component for a turbine engine is provided. The preform component includes a substrate. An outer coating is applied over the substrate. A characteristic of the outer coating is determined. Instructions for forming a cooling aperture are revised based on the characteristic of the outer coating to provide revised instructions. The cooling aperture is formed in the outer coating and the substrate based on the revised instructions.