Gas Turbine Vane Cooling Channels for Plugging-Resistant Heat Control
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Solution Overview
Problem
Existing turbine vane cooling designs face challenges in manufacturing complexity, limited applicability to 3D airfoil designs, and non-uniform temperature distribution, leading to reduced operational lifetime and efficiency.
Innovation Solution
A turbine vane design with radially extending cooling channels featuring alternating flow directions and integrated bypass channels to prevent plugging, combined with additive manufacturing for flexibility and durability, and a dust precipitator to ensure clean coolant supply.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If radially extending cooling channels are casted or drilled, then cooling effect is achieved, but manufacturing complexity increases and scrap rate becomes remarkably high
Solution Approach 1:
The cooling channels are segmented into multiple discrete radial openings distributed around the airfoil perimeter, allowing independent manufacturing of each channel while maintaining overall cooling effectiveness. This segmentation enables simpler manufacturing processes compared to monolithic casting or drilling of continuous radial channels.
2Ease of manufacture
If drilling is used for cooling holes, then manufacturing is simplified, but it is limited to airfoils with straight radial configuration which is now the exception
Solution Approach 1:
The cooling channel arrangement adapts dynamically to the specific 3D geometry of the airfoil through computer-aided design and additive manufacturing, allowing the channels to follow the curved and complex radial paths required by modern airfoil configurations rather than being constrained to straight radial arrangements.
Solution Approach 2:
Traditional mechanical drilling or casting processes are replaced with additive manufacturing technology, which can directly fabricate complex radial cooling channel geometries in 3D airfoil structures without requiring straight configurations or complex tooling, thereby achieving both manufacturing simplicity and geometric flexibility.
3Device complexity
If multiple axial regions with synchronized cooling flow directions are used, then cooling flow is simplified, but uniform temperature distribution is not achieved
Solution Approach 1:
Instead of using synchronized cooling flow directions in multiple axial regions, the invention inverts the approach by using alternating flow directions in adjacent radial cooling channels. This inversion creates a counter-flow arrangement that actively equalizes temperature distribution across the airfoil wall thickness, achieving uniform temperature distribution while maintaining relatively simple cooling flow arrangement.
4Reliability
If impingement cooling sheets are applied, then high cooling effect is achieved, but additional elements and joining processes are required which decrease reliability and increase costs
Solution Approach 1:
The cooling channels are merged directly into the airfoil structure as integrated features, eliminating the need for separate impingement cooling sheets and joining processes. The radial cooling channels are formed as part of the airfoil monolithic structure through additive manufacturing, achieving high cooling effectiveness while reducing component count and improving reliability.
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
Enhances operational lifetime and efficiency by achieving uniform temperature distribution and reducing the risk of channel plugging, while allowing for complex airfoil shapes and reducing coolant usage.
Implementation Method 1
a number of cooling channels that are arranged in the suction side wall and/or the pressure side wall, the cooling channels extends substantially in radial direction, wherein each cooling channel has at least one channel inlet and one channel outlet through which a coolant can enter resp. leave the respective cooling channel
Implementation Method 2
The cooling channel set enables a counter air flow arrangement in adjacent channels which leads to a more uniform metal temperature for the airfoil walls with less thermally induced stress
Data Source
AI summary
A turbine vane (TV) for a gas turbine includes an airfoil (AF) with a suction side wall (SSW) and a pressure side wall (PSW) that form a central cavity (CC). These walls extend axially from a leading edge (LE) to a trailing edge (TE) and radially from an outer end (OE) to an inner end (IE). The vane features outer and inner platforms (OP, IP) with hot and cold gas surfaces. Cooling channels (CMC) are arranged in the SSW and/or PSW, extending radially with inlets and outlets connected to coolant supply and discharge chambers. The channels are configured so adjacent channels have opposite flow directions, reducing the risk of plugging by particles. A bypass channel (BC) connects two adjacent cooling channels to mitigate clogging. The vane may include a dust precipitator (DP) with an air acceleration zone (AAZ), dust inertia separator (DIS), and dust trap (DT).