Turbine Cooling Passage Roughness for Higher Heat Transfer
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Solution Overview
Problem
Existing cooling designs for gas turbine components, such as rotor blades and vanes, do not provide sufficient cooling at all engine conditions, limiting the maximum working temperature of the engine.
Innovation Solution
A method of manufacturing components using laser sintering to create cooling passages with varying surface roughness, including micro and macro ribs, to enhance heat transfer and cooling efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional cooling designs with smooth internal passages are used, then manufacturing is simple, but cooling efficiency is insufficient at all engine conditions
Solution Approach 1:
The patent applies local quality by creating different surface roughness characteristics in different sections of the cooling passage. The first section has a first predetermined surface roughness while the second section has a second predetermined surface roughness, allowing each section to be optimized for specific cooling requirements at different engine conditions.
Solution Approach 2:
The cooling passage is segmented into multiple sections with different surface roughness characteristics. This segmentation allows the patent to address the technical contradiction by providing enhanced cooling efficiency in specific sections while maintaining manufacturing feasibility through controlled laser sintering parameters.
2Reliability
If uniform surface roughness is applied throughout the cooling passage, then manufacturing is easier, but heat transfer enhancement is insufficient in specific sections
Solution Approach 1:
The patent implements local quality by specifying different predetermined surface roughness values for different sections of the cooling passage. The first section has a first predetermined surface roughness and the second section has a second predetermined surface roughness, enabling localized heat transfer optimization.
Solution Approach 2:
The patent applies parameter changes by controlling the laser sintering process to achieve different surface roughness characteristics in different sections. This involves modifying laser parameters (power, speed, hatching distance) to create the desired surface roughness profile for optimal heat transfer in each section.
3Reliability
If laser sintering parameters are adjusted to create varying surface roughness, then heat transfer is enhanced, but manufacturing complexity increases
Solution Approach 1:
The patent utilizes parameter changes in the laser sintering process to create varying surface roughness. By adjusting laser power, scanning speed, and hatching distance, the patent achieves different surface roughness characteristics in different sections, enhancing cooling performance while using an established manufacturing process.
Solution Approach 2:
The patent applies preliminary action by designing the cooling passage with predetermined surface roughness characteristics built into the manufacturing process itself. The varying surface roughness is created during laser sintering before any post-processing, integrating the heat transfer enhancement directly into the manufacturing step.
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 method enhances heat transfer and cooling efficiency, allowing for higher operating temperatures and longer service life of gas turbine components without increasing air usage.
Implementation Method 1
manufacturing the component (100) using a laser sintering additive manufacture apparatus
Implementation Method 2
controlling the laser sintering additive manufacture apparatus dependent on a control parameter such that the first section (204A) has a first predetermined roughness
Data Source
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AI summary
A method of manufacturing a component (100) for a turbo machine. The component (100) comprises a main body (104) having a fluid inlet (103) and fluid outlet (200). A cooling passage (204) extends between a fluid inlet (103) and a fluid outlet (200). The cooling passage (204) is divided into a first (204A) and a second section (204B) which extend between the fluid inlet (103) and fluid outlet (200). The first section (204A) has a first predetermined roughness; and the second section (204B) has a second predetermined surface roughness; the predetermined surface roughness in at least one of the first section (204A) and second section (204B) is defined by a plurality of spaced apart micro ribs (212) which extend at least part of the way across the cooling passage (204), at least one of the cooling passage sections is formed to further comprise macro ribs (206) which extend across the cooling passage (204), at least one micro rib is being formed between adjacent macro ribs (206).