Turbine Airfoil Core Bosses for Plenum Positioning
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Solution Overview
Problem
Traditional methods for controlling the location and rib wall thickness of the center plenum in multiwall turbine airfoil castings, such as using bumpers, often result in uncertainties in cooling flow distribution due to potential gaps between the center plenum and outer cooling passages, leading to inefficiencies and increased complexity in measuring rib wall thickness.
Innovation Solution
Incorporating bosses extending from the center plenum section to the outer profile of the core, which are securely engaged by setter blocks to prevent movement and eliminate gaps, thereby controlling the position of the center plenum sections independently of the outer cooling passages, and using these bosses to determine the thickness of the inner wall without requiring expensive MRI measurements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If bumpers are used between the center plenum and outer cooling passages to control gap and rib wall thickness, then location control is achieved, but holes may form between cavities leading to uncertainty in cooling flow distribution
Solution Approach 1:
The invention removes the bumpers (disturbing elements) from the casting process and replaces them with a core featuring protrusions that directly define the center plenum location. This extraction eliminates the source of holes and flow distribution uncertainty while maintaining location control precision.
Solution Approach 2:
The core with protrusions serves as an intermediary element between the setter blocks and the final casting. The protrusions on the core act as precise location定义 features for the center plenum, mediating the positioning process without creating gaps or holes that would compromise cooling flow reliability.
2Manufacturing precision
If bumpers are used to limit the gap between center plenum and cooling passages, then position control is improved, but device complexity increases due to the need for additional measurement processes
Solution Approach 1:
The core with protrusions performs the dual function of defining both the center plenum location and the rib wall thickness. The protrusions self-definedly establish the precise positioning and thickness dimensions during casting, eliminating the need for separate, complex measurement processes to verify these critical dimensions.
Solution Approach 2:
The core structure serves multiple functions simultaneously: it defines the center plenum location, controls rib wall thickness, and ensures proper spacing between cooling passages. This multi-functionality consolidates what would otherwise require multiple separate control mechanisms and measurement processes into a single integrated solution.
3Ease of manufacture
If the center plenum position is allowed to move during firing, then ease of manufacture is improved, but manufacturing precision deteriorates due to gaps forming between cavities
Solution Approach 1:
The protrusions on the core are pre-formed to the exact dimensions and positions required for proper center plenum location. During assembly, these pre-formed protrusions automatically establish the correct positioning and prevent gap formation, eliminating the need for complex adjustment or constraint mechanisms during the firing process.
Solution Approach 2:
The invention removes the need for complex positioning mechanisms or constraints that would otherwise be required to prevent movement and gap formation during firing. By extracting the positioning function into the core's protrusion geometry itself, the process becomes simpler while maintaining precision.
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 ensures precise control over the center plenum position and rib wall thickness, preventing holes between cavities, reducing turbulence, and allowing for deterministic cooling flow, thereby enhancing the performance and output of gas turbines by eliminating the need for bumpers and simplifying thickness measurement processes.
Implementation Method 1
heating the core
Data Source
Figure 1
Figure 2~5
Figure 3
AI summary
A core 10 for a turbine airfoil casting according to an embodiment includes: a center plenum section 24; and a plurality of outer passage sections 26; wherein the center plenum section 24 includes at least one boss extending outwardly from the center plenum 24 to an outer profile of the core 10.