Two-Piece Vane Baffle With Trailing-Edge Cooling Holes
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Solution Overview
Problem
Existing gas turbine engine baffles often lack cooling holes near the trailing edge of airfoil vanes due to manufacturing limitations, resulting in reduced cooling efficiency at this critical area.
Innovation Solution
A baffle design featuring a leading edge portion formed through additive manufacturing and a trailing edge portion made of sheet metal, both with cooling holes, bonded at a joint with a step that defines a weld surface, to enhance cooling air distribution and efficiency across the airfoil vane.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional manufacturing methods are used for baffles, then manufacturing simplicity is maintained, but cooling holes cannot be provided near the trailing edge of airfoil vanes
Solution Approach 1:
The baffle is divided into two separate portions: a leading edge portion formed by additive manufacturing and a trailing edge portion formed by sheet metal. This segmentation allows each portion to be manufactured using the most appropriate method for its specific requirements, enabling cooling holes near the trailing edge while maintaining manufacturing feasibility.
Solution Approach 2:
Different portions of the baffle are manufactured using different methods tailored to their specific needs. The leading edge portion uses additive manufacturing to accommodate complex cooling hole patterns, while the trailing edge portion uses sheet metal for ease of fabrication and assembly.
2Reliability
If additive manufacturing is used for the entire baffle, then cooling holes near the trailing edge can be provided, but manufacturing cost and complexity increase
Solution Approach 1:
The patent applies different manufacturing methods to different portions of the baffle based on local requirements. The leading edge portion requires additive manufacturing to achieve the necessary cooling hole configuration, while the trailing edge portion can use simpler sheet metal fabrication, thus achieving reliable cooling without unnecessary manufacturing complexity throughout the entire component.
Solution Approach 2:
By segmenting the baffle into two portions manufactured by different processes, the patent achieves high cooling efficiency where needed (leading edge with additive manufacturing) while maintaining manufacturing simplicity where possible (trailing edge with sheet metal).
3Strength
If a single-piece baffle is used, then structural integrity is simplified, but cooling air distribution to the trailing edge is insufficient
Solution Approach 1:
The baffle is segmented into a leading edge portion and a trailing edge portion that are bonded together. This segmentation enables the trailing edge portion to include cooling holes for improved cooling efficiency while the bonding joint maintains sufficient structural integrity for the application.
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 design improves cooling efficiency at the trailing edge of airfoil vanes by providing impingement cooling through strategically placed cooling holes, overcoming manufacturing limitations and enhancing the overall performance of gas turbine engines.
Implementation Method 1
Both the leading edge portion and the trailing edge portion include a plurality of cooling holes which are configured to provide cooling air to the airfoil outer wall
Implementation Method 2
a leading edge portion and a separate trailing edge portion which are bonded to one another at a joint
Data Source
AI summary
An airfoil vane includes an airfoil section which includes an outer wall that defines an internal cavity. A baffle is situated in the internal cavity. The baffle includes a leading edge portion and a trailing edge portion which is bonded to the leading edge portion at a joint. The leading edge portion and the trailing edge portion define an internal cavity therewithin. Both the leading edge portion and the trailing edge portion include a plurality of cooling holes which are configured to provide cooling air to the airfoil outer wall. The trailing edge portion is formed of sheet metal and the leading edge portion is formed of non-sheet-metal. A method of making a baffle for a vane arc segment and a method of assembling a ceramic matrix composite airfoil vane are also disclosed.