Turbine Nozzle Unitary Ring Oxide Braze Joint
Solution Overview
Problem
Conventional turbine nozzles with segmented inner and outer rings suffer from gas leakage, increasing fuel consumption and manufacturing complexity, particularly in applying thermal barrier coatings, while bi-cast rings are difficult and time-consuming to produce.
Innovation Solution
A turbine nozzle design featuring a single unitary ring and vane with slip joints and bonded joints, utilizing an oxide layer and braze material to minimize gas leakage and simplify manufacturing, allowing for retrofitting into existing engines.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If segmented inner and outer rings are used to simplify manufacture, then manufacturing complexity is reduced, but gas leakage occurs at segment interfaces
Solution Approach 1:
The patent applies segmentation by dividing the turbine nozzle into modular segments that can be manufactured separately and assembled together. The segments include nozzle vanes and ring portions with standardized interfaces, allowing simplified manufacturing while maintaining gas tightness through precision-machined mating surfaces and interference fit connections.
2Reliability
If bi-cast inner and outer rings are used to reduce leakage, then gas leakage is reduced, but manufacturing becomes difficult and time-consuming
Solution Approach 1:
Instead of using complex bi-cast technology, the patent segments the rings into separate manufacturable portions that are assembled using standardized joint interfaces. This allows gas tightness to be achieved through precision machining and interference fits rather than requiring difficult bi-cast manufacturing processes.
Solution Approach 2:
The patent introduces intermediary joint structures including braze layers and oxide layers at the interfaces between ring segments and nozzle vanes. These intermediary layers facilitate gas-tight connections while allowing the components to be manufactured separately using conventional processes.
3Reliability
If bi-cast turbine nozzles are used, then gas leakage is reduced, but application of thermal barrier coatings becomes complex
Solution Approach 1:
By segmenting the turbine nozzle into separate manufacturable components with standardized interfaces, the patent enables thermal barrier coatings to be applied to each segment independently using conventional deposition techniques. This avoids the coating complexity associated with bi-cast structures while maintaining gas tightness through precision interfaces.
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 design reduces gas leakage, simplifies manufacturing, and enables efficient application of thermal barrier layers, improving fuel efficiency and reducing production costs while maintaining engine performance.
Implementation Method 1
a first joint is formed in the first opening between the first ring and the vane and includes a first braze layer and an oxide layer
Implementation Method 2
the first joint is formed in the first opening between the first ring and the vane and includes a first braze layer and an oxide layer
Data Source
AI summary
Turbine nozzles and methods of manufacturing the turbine nozzles are provided. In an embodiment, by way of example only, a turbine nozzle includes a first ring, a vane, and a first joint. The first ring comprises a single unitary component and having a first opening and including a first metal alloy. The vane includes a first end disposed in the first opening and includes a second metal alloy. The first joint is formed in the first opening between the first ring and the vane and includes a first braze layer and an oxide layer. The first braze layer is disposed adjacent to the oxide layer, and the first braze layer and the oxide layer are disposed between the first ring and the vane.