Turbine Vane Assembly Seal Weld and Cooling Channel Design
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Solution Overview
Problem
Current gas turbine engine airfoils face limitations in withstanding high temperature gas flows due to material properties and cooling capabilities, leading to reduced efficiency and shortened component life, particularly in the first stage where temperature is highest.
Innovation Solution
The vane assembly incorporates a seal weld in the second stator vane cooling channel to isolate it from the inner fluid channel, along with upper and lower attachment rails connecting the stator vanes, enhancing structural support and cooling air flow management, while maintaining manufacturability considerations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If higher temperature gas flow is passed through the turbine to increase efficiency, then engine efficiency is improved, but the vane and blade materials and cooling capabilities are exceeded leading to reduced component life
Solution Approach 1:
The vane assembly is divided into multiple vanes (first stator vane, second stator vane) that can be manufactured separately and then joined together. This segmentation allows for optimized cooling channel designs in each individual vane while maintaining the ability to withstand high temperatures collectively, thus enabling higher operating temperatures without compromising component life
Solution Approach 2:
The cooling channels are nested within the vane structure itself, with cooling passages integrated into the buttresses and vane bodies. This nested configuration allows cooling air to flow through internal passages within the vanes, providing internal cooling that enables the vanes to withstand higher external temperatures while maintaining material integrity and extending component life
2Temperature
If cooling channels are added to manage thermal loads, then thermal management is improved, but manufacturing complexity increases
Solution Approach 1:
The cooling system is segmented into multiple independent cooling channels located in different regions (first stator vane cooling channel, second stator vane cooling channel, cross vane cooling transfer channel). This segmentation allows each cooling channel to be designed and manufactured independently using standard casting techniques, then assembled together, reducing overall manufacturing complexity while providing comprehensive thermal management
Solution Approach 2:
The buttresses serve multiple functions: they provide structural support to the vanes and simultaneously contain the cooling channels within their structure. This multi-functionality reduces the need for separate cooling components, simplifying the overall manufacturing process while maintaining effective thermal management capabilities
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 configuration improves the thermal management and structural integrity of the airfoils, allowing for higher operating temperatures and increased efficiency without compromising manufacturing feasibility, thus extending component life and enhancing engine performance.
Implementation Method 1
a seal weld disposed in the second stator vane cooling channel, whereby the second stator vane cooling channel is isolated from the inner fluid channel
Implementation Method 2
cooling air flow management
Implementation Method 3
thermal management and structural integrity of the airfoils
Data Source
Figure 1
Figure 2
Figure 3
AI summary
An airfoil of a turbine engine (2) may have internal passages to permit the travel of cooling air through the airfoil. Multiple airfoils may be formed together in a stator vane assembly (52), and cooling air may be directed through the stator vane assembly (52). The stator vane assembly (52) may be mounted to an engine structure to carry structural loads experienced by the stator vane assembly (52). Buttresses (56-1, 56-2) may be formed in the stator vane assembly (52), such as beneath each airfoil of the stator vane assembly (52), and extending into a passage (55) permitting the travel of cooling air through the airfoil. The buttresses (56-1, 56-2) may enhance the strength and stability of the stator vane assembly (52) by facilitating the transmission of structural loads to an engine structure. A channel (57-1, 57-2) may be defined through one or more buttress (56-1, 56-2) to enable the passage of cooling air into the airfoils, and yet allow the buttresses (56-1, 56-2) to carry structural loads.