Turbine Hot Gas Path Cooling Channels Near the Surface
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Solution Overview
Problem
The existing methods for forming cooling channels in hot gas path components of turbines limit their proximity to the surface, reducing their effectiveness and increasing thermal stress due to high temperatures, which can cause degradation, creep, oxidation, and thermal fatigue.
Innovation Solution
A method involving the formation of cooling channels in hot gas path components using a brazing process, where channels are created in the component surface and filled with a filler material, then covered with a layer, allowing for a closer proximity to the surface and improved cooling efficiency by directing a cooling fluid through these channels.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If cooling channels are formed by casting, then the component structure is simple, but the proximity of channels to the surface is limited, reducing cooling effectiveness
Solution Approach 1:
The component is divided into multiple segments or layers, with cooling channels formed in separate sections that can be positioned closer to the surface. This segmentation allows independent optimization of channel placement without compromising overall structural integrity.
Solution Approach 2:
The cooling channels are positioned in multiple dimensional layers within the component, with some channels placed extremely close to the outer surface in specific zones. This multi-dimensional arrangement allows channels to achieve proximity to surface areas that would be inaccessible with conventional single-layer casting methods.
2Temperature
If cooling channels are positioned closer to the surface, then cooling effectiveness improves, but thermal stress and component degradation increase
Solution Approach 1:
Different regions of the component have different cooling channel configurations. Areas experiencing highest thermal loads have channels positioned closer to the surface for maximum cooling effectiveness, while other regions maintain more traditional channel placement to preserve structural strength and minimize thermal stress concentration.
Solution Approach 2:
The diameter, spacing, and depth of cooling channels are varied as parameters to optimize the balance between cooling effectiveness and structural integrity. By adjusting these parameters locally, the system achieves improved surface cooling while maintaining adequate material thickness to withstand thermal stresses.
3Ease of manufacture
If conventional casting methods are used, then manufacturing process is simple, but thermal stress and component degradation from high temperatures increase
Solution Approach 1:
Cooling channels are pre-positioned and pre-cooled areas are established before the component undergoes thermal processing or operation. This preliminary cooling infrastructure is built into the component design, allowing thermal stresses to be managed from the outset rather than requiring complex post-processing or operational adjustments.
Solution Approach 2:
The cooling channels act as intermediary structures that mediate between the hot gas path and the component interior. By introducing cooling fluid through these channels, thermal energy is intercepted and removed before it can cause excessive thermal stress or degradation, protecting the component while maintaining manufacturing simplicity.
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 enhances cooling efficiency, reduces thermal fatigue, and extends the service life of turbine components by maintaining a uniform temperature distribution and improving the overall performance of the turbine system.
Implementation Method 1
A method involves brazing a layer to a component
Implementation Method 2
directing a cooling fluid through these channels
Data Source
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AI summary
According to one aspect of the invention, a method for manufacturing a hot gas path component of a turbine is provided, the method including forming cooling channels in a surface of a member. The method also includes disposing a layer on the surface of the member to enclose the cooling channels, the layer being disposed on a portion of the member to be cooled and bonding the layer to the surface, wherein bonding comprises heating the member and the layer.