Turbine Vane Cooling Passage Design for Thermal Management
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Solution Overview
Problem
Gas turbine engine airfoils face challenges due to the high-temperature resistance and strength limitations of composite materials, which are not adequately addressed by existing cooling methods, particularly in maintaining structural integrity and efficient heat transfer.
Innovation Solution
A turbine vane assembly incorporating a ceramic matrix composite airfoil with a metallic spar and ribs that form a cooling passage, where the spar includes a feed duct and turbulators to distribute cooling gas and enhance heat transfer, addressing the limitations of existing cooling methods by providing structural support and efficient heat management.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If ceramic matrix composite materials are used for the airfoil to withstand high temperatures, then temperature resistance is improved, but structural strength and load-bearing capacity deteriorate
Solution Approach 1:
The invention uses a composite structure combining ceramic matrix composite airfoil with a metallic spar. The ceramic airfoil provides high-temperature resistance while the metallic spar embedded within it provides structural strength and load-bearing capacity, resolving the contradiction between temperature resistance and structural strength
Solution Approach 2:
The airfoil is segmented into different functional zones: the outer ceramic matrix composite material for thermal protection and the inner metallic spar for structural support. This segmentation allows each material to perform its optimal function without compromising the other
2Use of energy by moving object
If cooling passages are formed in the airfoil to manage heat, then heat transfer efficiency is improved, but structural integrity and manufacturing complexity worsen
Solution Approach 1:
The cooling passages are pre-formed within the metallic spar structure before final assembly. The feed duct and cooling passages are integrated into the spar's manufacturing process, eliminating the need for complex post-assembly operations and reducing overall manufacturing complexity
Solution Approach 2:
The cooling passage system is merged with the metallic spar structure. The spar serves dual purposes: providing structural support and housing the cooling passages, thereby integrating thermal management functionality into the load-bearing structure without adding separate complex cooling systems
3Strength
If a metallic spar is embedded in the ceramic airfoil to provide structural support, then structural integrity is improved, but heat transfer efficiency and manufacturing difficulty worsen
Solution Approach 1:
The manufacturing process is segmented into distinct phases: first forming the ceramic airfoil structure, then embedding the pre-fabricated metallic spar with integrated cooling passages. This segmentation allows each component to be optimized and manufactured separately using appropriate processes, reducing overall manufacturing difficulty
Solution Approach 2:
The metallic spar acts as an intermediary element that bridges the ceramic airfoil structure and the cooling system. It provides a suitable medium for heat transfer while maintaining structural integrity, and its modular design facilitates easier integration compared to monolithic designs
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 solution effectively manages heat transfer and structural integrity, enabling the airfoil to withstand high temperatures while maintaining operational efficiency and reliability in gas turbine engines.
Implementation Method 1
The cooling gas flow through the cooling passage formed by the spar and the inner surface of the airfoil to cool the airfoil
Implementation Method 2
The spar includes a feed duct that extends radially into the spar and a feed hole that extends through the spar. The feed hole fluidly connects the feed duct with the cooling passage which allows cooling gas to flow from the feed duct into the cooling passage to cool the airfoil
Data Source
Figure 1~2
Figure 3
Figure 4~5
AI summary
A turbine vane assembly adapted for use with a gas turbine engine includes an airfoil and a spar. The airfoil is formed to define a cavity that extends into the airfoil. The spar is located in the cavity to define a cooling passage that extends around the spar between the spar and the airfoil. The turbine vane assembly includes cooling features to aid heat transfer of the turbine vane assembly during operation in the gas turbine engine.