Vane Assembly Integrated Nozzle Tube CMC Cooling
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Solution Overview
Problem
Implementing ceramic matrix composite (CMC) materials in gas turbine airfoils poses unique challenges, despite their high temperature resistance, due to integration and leakage issues with cooling systems.
Innovation Solution
A vane assembly design featuring a ceramic matrix composite airfoil fairing supported by a high-temperature resistant spar, with an integrated support structure that includes a nozzle tube and annular plenum for efficient cooling air delivery, reducing leakage and thermal insulation, and a method of assembly that secures the spar leg to the support platform for enhanced structural integrity and reduced interfaces.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If ceramic matrix composite materials are used in airfoils to achieve high temperature resistance, then temperature capability is improved, but integration and leakage issues with cooling systems occur
Solution Approach 1:
The patent merges the nozzle tube and support platform into a single integrated component. The support platform includes an integrated nozzle tube extending from its second side, eliminating the need for separate nozzle tube and support components. This integration reduces leakage paths and improves reliability while maintaining high temperature resistance through the CMC airfoil fairing.
Solution Approach 2:
The patent introduces an intermediary sealing structure at the interface between the spar leg and support platform. A seal is provided around the spar leg in the opening of the support platform, creating a leak-tight interface that mediates between the CMC airfoil fairing and the cooling system components, preventing cooling air leakage while maintaining thermal isolation.
2Ease of manufacture
If separate nozzle tube and support platform components are used, then ease of manufacture is improved, but leakage and thermal insulation are worsened
Solution Approach 1:
The nozzle tube and support platform are combined into a single monolithic component. The support platform is formed with the nozzle tube extending directly from its second side, creating an integrated structure that eliminates leakage paths between components while maintaining manufacturability through single-piece fabrication or modular assembly of the integrated unit.
3Ease of operation
If multiple interfaces are provided in the support structure, then ease of assembly is improved, but leakage and structural integrity are worsened
Solution Approach 1:
The support platform and nozzle tube are merged into a single integrated component, reducing the number of interfaces between separate parts. This integration eliminates leakage paths at interfaces while maintaining assembly flexibility through the modular nature of the vane assembly, where the integrated support structure is installed as a complete unit.
Solution Approach 2:
A seal acts as an intermediary element at the interface between the spar leg and support platform opening. This seal provides leak-tight sealing while allowing for assembly flexibility, mediating between the need for multiple interfaces in modular assembly and the requirement for leak prevention and structural integrity.
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 addresses integration and leakage issues, enhancing the efficiency and reliability of CMC airfoils in gas turbines by providing a sealed and thermally insulated cooling system, thereby improving engine performance and reducing maintenance needs.
Implementation Method 1
A cooling air passage is provided through the spar leg and the nozzle tube. The cooling air passage communicates with the through-cavity of the airfoil fairing such that cooling air may be delivered into the through-cavity.
Implementation Method 2
Airfoils in the turbine section are typically formed of a superalloy and may include thermal barrier coatings to extend temperature capability and lifetime. Ceramic matrix composite ('CMC') materials are also being considered for airfoils. Among other attractive properties, CMCs have high temperature resistance.
Data Source
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AI summary
A vane assembly (60) includes an airfoil fairing (62) that has first and second fairing platforms (66, 68) and a hollow airfoil section (64) that extends therebetween. A spar (72) has a spar leg (72b) that extends through the hollow airfoil section (64). The spar leg (72b) has a through-passage (72c) and an end portion (74) that protrudes from the second fairing platform (68). A support (76) is secured with the end portion (74) of the spar leg (72b). The support (76) has a platform (78) that includes first and second sides (78a, 78b), an opening (78c) that extends between the first and second sides (78a, 78b), and a nozzle tube (80) that extends from the second side (78b). The first side (78a) is adjacent the second fairing platform (68). The end portion (74) of the spar leg (72b) is disposed in the opening (78c) so as to fluidly connect the through-passage (72c) with the nozzle tube (80).