Gas Turbine Cooling Insert for Hot Spot Airflow Control
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Solution Overview
Problem
Conventional cooling cores for gas turbine hot gas path components are expensive, limiting cost-effectiveness and efficiency in cooling high-temperature components like airfoils, buckets, and nozzles, which necessitates a more economical and efficient cooling solution.
Innovation Solution
A 'mini-core' or insert is designed to be integrated into the hot gas path components, featuring a unitary construction with flow modification features and formed through additive manufacturing, providing a cost-effective cooling solution by creating a cavity and passageway system for enhanced cooling airflow, and optionally coated with thermal barrier coatings for improved performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional cooling cores are used for gas turbine hot gas path components, then cooling effectiveness is achieved, but manufacturing cost increases significantly
Solution Approach 1:
The cooling solution is divided into two segments: a reusable metal component housing and disposable inserts made from inexpensive materials (ceramic, metal foam, or refractory concrete). This segmentation allows the expensive metal housing to be used repeatedly while the inexpensive inserts are replaced as needed, significantly reducing overall manufacturing costs while maintaining cooling effectiveness.
Solution Approach 2:
The patent employs disposable inserts made from low-cost materials such as ceramic, metal foam, or refractory concrete that can be easily manufactured and replaced. These inserts are designed to be temporary cooling elements that protect the expensive metal housing during high-temperature operation, then are discarded and replaced rather than repaired or reused.
2Temperature
If material modifications and coatings are applied to protect components from high temperatures, then operating temperature limits increase, but manufacturing complexity and cost increase
Solution Approach 1:
The thermal protection function is extracted from the main metal component and implemented as separate, removable inserts. This allows the metal housing to be simpler in design while the thermal protection is provided by specialized materials (ceramic, metal foam, or refractory concrete) that are easily manufactured as standalone elements and inserted into the housing.
Solution Approach 2:
The patent utilizes composite material structures, particularly metal foam inserts that combine metallic properties with porous thermal management capabilities. These composite materials provide both structural support and thermal protection in a single element, reducing the need for additional coatings or modifications to the base metal component.
3Reliability
If cooling structures are added to hot gas path components, then cooling capability is improved, but component weight increases
Solution Approach 1:
The patent employs porous materials such as metal foam and ceramic foam as inserts within the cooling channels. These porous structures provide extensive surface area for heat transfer while maintaining low weight. The porous structure allows cooling air to flow through and contact the hot gas path component walls efficiently, providing superior cooling capability per unit weight compared to solid cooling structures.
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
The mini-core insert enhances cooling efficiency, increases operating temperature limits, extends the service life of components, and reduces costs by providing effective cooling to high-temperature components, particularly in areas prone to 'hot spots', while maintaining structural integrity.
Implementation Method 1
cavity and passageway system for enhanced cooling airflow
Implementation Method 2
providing cooling to portions of hot gas path components
Implementation Method 3
optionally coated with thermal barrier coatings for improved performance
Data Source
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AI summary
A method of providing cooling structure for a component (10) comprising forming a first cavity in the component (10) and forming a first passageway in the first cavity in fluid communication with a second cavity (16) positioned inside the component (10), the second cavity (16) in fluid communication with a cooling air source. The method further includes forming a unitary insert (20) including a first surface and a second surface; the insert (20) having an inlet formed in the first surface and an outlet formed in the second surface and a second passageway in fluid communication with the inlet and the outle. The method further includes positioning the insert (20) in the first cavity into fluid communication with the first passageway, the first surface facing the first cavity and rigidly attaching the insert in the first cavity.