Additive Sealing Insert for Turbine Cooling Compartmentalization
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Solution Overview
Problem
Conventional manufacturing methods for turbine airfoil components, such as milling, struggle to efficiently integrate complex cooling features and sealing mechanisms, limiting their cooling effectiveness and manufacturing efficiency.
Innovation Solution
The use of laser-sintered sealing inserts with compressible seals that expand under pressure differential to create a compression force, facilitating fluid communication and compartmentalization within the turbine component, enabling effective cooling and manufacturing through additive manufacturing processes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If conventional manufacturing methods (milling, cutting) are used to manufacture turbine airfoil components, then manufacturing processes are well-established and controllable, but the ability to integrate complex cooling features and sealing mechanisms is limited and manufacturing efficiency is reduced
Solution Approach 1:
The sealing insert integrates multiple functions including sealing, cooling fluid distribution, and structural support into a single component. The insert combines seal elements, cooling channels, and mounting features that would traditionally require separate components, thereby simplifying the overall assembly and improving manufacturing efficiency.
Solution Approach 2:
The sealing insert is designed with nested cooling channels and compartments within its structure. The compressible seal is positioned within a recess, and cooling fluid pathways are integrated within the insert body, allowing multiple functional elements to be nested within a compact geometry.
2Shape
If laser-sintered sealing inserts with compressible seals are used, then complex geometries are achieved and cooling efficiency is enhanced, but manufacturing process complexity increases
Solution Approach 1:
The compressible seal utilizes pressure-induced parameter changes to transition from a compressed installation state to an expanded sealing state. When cooling fluid pressure differential acts on the seal, it expands to create the sealing force necessary for effective sealing, allowing the same component to serve both installation and sealing functions.
Solution Approach 2:
The compressible seal is designed to self-adjust and self-seal based on the operating pressure conditions. The seal automatically expands to the required sealing pressure when cooling fluid flows through the insert, eliminating the need for external adjustment mechanisms or complex control systems.
3Reliability
If compressible seals expanding under pressure differential are used, then reliable sealing is created and fluid distribution is improved, but the seal design complexity increases
Solution Approach 1:
The compressible seal is actuated by the pressure differential of the cooling fluid itself. The cooling fluid pressure acts on the seal to expand it against the sealing surface, utilizing the existing hydraulic pressure of the system rather than requiring separate actuation mechanisms.
Solution Approach 2:
The compressible seal employs a flexible bellows-like structure that can expand and contract in response to pressure changes. This flexible geometry allows the seal to adapt to pressure variations and maintain reliable sealing without requiring complex rigid mechanisms.
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 enhances the cooling efficiency of turbine components by creating a reliable seal and pressure-driven fluid distribution, while leveraging additive manufacturing for complex geometries and reduced material waste, improving both performance and manufacturing speed.
Implementation Method 1
the cooling fluid inlets and outlets cause a pressure differential between the insert interior space and the cooling compartments
Implementation Method 2
the pressure differential expands the compression seal and enables the compression seal to create a compression force which engages the compression seal with the inner surface of the component wall
Implementation Method 3
additive manufactured seal for insert compartmentalization in a turbine component
Data Source
Figure 1
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AI summary
Aspects of the disclosure include a sealing insert (150, 175, 200, 400), turbine component (100, 350, 410), and code for manufacturing a sealing insert (100, 350, 410). A sealing insert (100, 350, 410) includes at least one insert wall (152, 176, 200, 210, 308, 402) for insertion proximate a component (100, 350, 410) wall to define a space between the at least one insert wall (152, 176, 200, 210, 308, 402) and the component (100, 350, 410) wall. At least one compressible seal (200) (300, 420, 440, 460) is provided between the at least one insert wall (152, 176, 200, 210, 308, 402) and the component (100, 350, 410) wall. The compressible seal or seals (200) (300, 420, 440, 460) divide the space into a plurality of compartments.