Turbine Stator Vane Platform Cooling via Cast Cavity and Welded Plate
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Solution Overview
Problem
Current high-level cooling technologies for turbine airfoil platforms are complex and expensive to implement, requiring a four-piece wax assembly that is not production-friendly.
Innovation Solution
A turbine engine component with a platform cavity formed by casting, featuring an as-cast open cavity with a plate welded over an entrance area, creating a cooling circuit that allows cooler air to flow through and exit onto the hot gas path side, enhancing heat transfer with turbulence-inducing protuberances and trip strips.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If a miniature core is placed within the platform wall to create cooling circuits, then heat transfer capability is improved, but device complexity and manufacturing cost increase significantly
Solution Approach 1:
The patent removes the complex miniature core from the platform wall entirely. Instead, it extracts the cooling function to the airfoil cavity by forming a simple open cavity that allows cooling air to flow directly across the platform surface, eliminating the need for intricate internal cooling circuits while maintaining effective heat transfer.
Solution Approach 2:
The cooling function is segmented from the platform wall structure. Rather than embedding cooling circuits within the platform, the system separates the cooling air flow path through the airfoil cavity from the platform cooling surface, allowing independent optimization of each component.
2Temperature
If a miniature core with cooling fins and pins is suspended in the platform wall, then cooling effectiveness is improved, but ease of manufacture deteriorates
Solution Approach 1:
The patent extracts the cooling function from the complex suspended core assembly and implements it through a simple open cavity in the platform. This allows the cooling structure to be formed directly during the casting process without requiring separate assembly steps for cores, fins, and pins.
Solution Approach 2:
The cooling cavity is formed as an integral part of the platform during the initial casting process. The cavity structure includes pre-formed turbulence-inducing features such as ribs and protuberances that are created during casting, eliminating the need for post-casting assembly of cooling components.
3Temperature
If a four-piece wax assembly is used to form the cooling structure, then cooling performance is improved, but productivity and production efficiency decrease
Solution Approach 1:
The patent merges the cooling cavity structure with the platform and airfoil as a single integrated component. The cavity is formed directly in the casting mold along with the platform and airfoil, eliminating the need for separate wax assemblies and reducing the number of production steps to a single casting operation.
Solution Approach 2:
The cooling cavity and its turbulence-inducing features are pre-formed during the casting process itself. The mold includes the cavity geometry and internal rib structures, allowing the complete cooling structure to be created in one casting operation without subsequent assembly or attachment steps.
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 approach provides an inexpensive and effective cooling solution by forming a turbine engine component with a platform cavity that enhances heat transfer and reduces implementation complexity, allowing for efficient cooling of turbine vanes.
Implementation Method 1
The air is evacuated out onto the gas path surface where the air spreads out on the surface to create a thin film of cooler air to help further protect the surface from hot gas path air
Implementation Method 2
The core has holes of varying shape in it that helps create turbulent air flow within the cavity and increase surface area thereby increasing the heat transfer capability of the air
Data Source
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AI summary
A turbine engine component (100) has an airfoil portion (108), which airfoil portion is bounded by a platform (104) at one end. The platform (104) has an as-cast open cavity (102) bordered by at least one as-cast landing (142). A plate (122) is welded to the at least one as-cast landing (142) to cover and close the as-cast open cavity (102). The invention also extends to a process for forming the turbine engine component (100).