Turbine Vane Integral Insert Supports Casting

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Solution Overview

Problem

The manufacturing of turbine vanes with insert support structures is challenging due to the complexity of the turbine design, requiring precise positioning and welding of numerous supports, which increases costs and vulnerability to defects, especially in high-temperature environments like H-class gas turbines.

Innovation Solution

A turbine vane design where insert supports are integrated into the main body through a casting process, forming a unitary structure with multiple insert supports arranged in a circumferential and radial direction, providing a stable 3-point or 4-point support configuration, reducing the need for additional manufacturing steps and minimizing vibration.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If numerous insert supports are separately manufactured and welded to the turbine vane, then the insert can be supported, but the manufacturing complexity and cost increase significantly

Engineering Contradiction:

Improveinsert support stabilityVSAvoidmanufacturing process complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The insert supports are integrated directly into the turbine vane body through the casting process, merging two separate manufacturing operations (casting the vane and manufacturing supports) into a single unified process. This eliminates the need for separate support manufacturing and welding operations, reducing manufacturing complexity while maintaining support stability.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The insert supports are formed as integral parts of the turbine vane during the initial casting process, rather than being added as post-processing steps. This preliminary formation of supports during casting eliminates subsequent welding operations and reduces the overall manufacturing process complexity.

Inventive Principle:

Principle #10Preliminary action

2Reliability

If numerous insert supports are separately manufactured and welded to the turbine vane, then the insert can be supported, but the manufacturing cost increases

Engineering Contradiction:

Improveinsert support stabilityVSAvoidmanufacturing cost

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

Inventive Principle:

Principle #10Preliminary action

3Reliability

If numerous insert supports are separately manufactured and welded to the turbine vane, then the insert can be supported, but the vulnerability to defects increases in high-temperature environments

Engineering Contradiction:

Improveinsert support stabilityVSAvoidvulnerability to defects in high-temperature environment

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The patent converts the potential harm of welding (which creates defect-prone joints in high-temperature environments) into a benefit by eliminating welding entirely. The integral casting process produces a homogeneous structure without weak joints, transforming the manufacturing approach to avoid the harmful effects of welding in high-temperature service conditions.

Inventive Principle:

Principle #22Blessing in disguise (Convert harm into benefit)

4Ease of manufacture

If insert supports are integrated into the main body through casting, then manufacturing is simplified, but precise positioning of supports must be achieved during casting

Engineering Contradiction:

Improvemanufacturing process simplificationVSAvoidinsert support positioning precision

Core Design Contradiction:

Ease of manufactureVSManufacturing precision

Solution Approach 1:

Inventive Principle:

Principle #10Preliminary action

Data Source

PatentUS11098602B2Turbine vane equipped with insert support

Publication Date: 2021.08.24 DOOSAN HEAVY IND & CONSTR CO LTD

AI summary

Disclosed is a turbine vane having a turbine vane airfoil extending from a platform to an end wall and having an airfoil-shaped cross section having a leading edge, a trailing edge, and a pressure side and a suction side that extend from the leading edge to the trailing edge, wherein a plurality of cavities defined by a plurality of ribs extending from the pressure side to the suction side is formed in the turbine vane airfoil, at least one of the cavities is provided with a plurality of insert supports protruding inward from an inner surface of the turbine vane airfoil, and the insert supports are arranged in a circumferential direction of the cavity and arranged in a plurality of rows arranged in a radial direction.