Patent Grant
11415002
A gas turbine engine typically includes a fan section, a compressor section, a combustor section and a turbine section. Air entering the compressor section is compressed and delivered into the combustion section where it is mixed with fuel and ignited to generate a high-energy exhaust gas flow. The high-energy exhaust gas flow expands through the turbine section to drive the compressor and the fan section. The compressor section typically includes low and high pressure compressors, and the turbine section includes low and high pressure turbines.
Any of the fan section, the turbine section, and the compressor section include airfoils, such as for fan, compressor, or turbine blades. Baffles are known and used in cooled gas turbine engine airfoils, such as turbine vanes. Typically, a baffle is situated in a cavity in the airfoil and serves to distribute cooling air to precise locations in the airfoil.
An airfoil component according to an exemplary embodiment of this disclosure, among other possible things includes an vane airfoil, which has a ceramic matrix composite airfoil section including an outer wall that defines an internal cavity. The vane airfoil has an associated temperature profile which defines at least one high temperature area and at least one low temperature area. The vane airfoil includes a first zone which is defined in a first radial extent and corresponds to the high temperature area of the temperature profile and a second zone defined in a second radial extent and corresponds to the low temperature area of the temperature profile. An insert is situated in the internal cavity. The insert includes a first zone defined in a first radial extent that is aligned with the first zone of the vane airfoil. The first zone includes a first plurality of cooling holes which are configured to provide a first cooling density. A second zone is defined in a second radial extent that is aligned with the second zone of the vane airfoil. The second zone includes a second plurality of cooling holes that provide a second cooling density that is lower than the first cooling density such that the high temperature area and the low temperature area are balanced to lower a thermal gradient across the first and second zones of the vane airfoil.
In a further example of the foregoing, the high temperature area and low temperature area correspond to an airfoil section of the vane airfoil.
In a further example of any of the foregoing, the first plurality of cooling holes have a first hole distribution density thereby providing the first cooling density. The second plurality of cooling holes have a second hole distribution density which provide the second cooling density. The first hole distribution density is different from the second hole distribution density.
In a further example of any of the foregoing, the first plurality of cooling holes have a first cumulative cross-sectional area which provides the first cooling density. The second plurality of cooling holes have a second cumulative cross-sectional area which provides the second cooling density. The first cumulative cross-sectional area is different from the second cumulative cross-sectional area.
In a further example of any of the foregoing, one of the first and second cooling densities is zero, and the other of the first and second cooling densities is nonzero.
In a further example of any of the foregoing, at least one rib extends in a radial direction on the insert.
In a further example of any of the foregoing, the airfoil component includes a transition zone between the first and second zones of the insert. The transition zone includes a gradual change in cooling density from the first cooling density to the second cooling density in a radial direction.
In a further example of any of the foregoing, the vane airfoil includes a third zone. The third zone is defined in a third radial extent of the vane airfoil. The insert includes a third zone which is defined in a third radial extent that is aligned with the third zone of the vane airfoil. The third zone of the insert includes a third plurality of cooling holes that provide a third cooling density. The third cooling density being different from at least one of the first and second cooling densities.
An vane airfoil according to an exemplary embodiment of this disclosure, among other possible things includes an airfoil section which includes an outer wall that defines an internal cavity. An insert is situated in the internal cavity. The insert includes a first zone which is defined in a radial extent of the insert. The first zone includes a first plurality of cooling holes, and a second zone is defined in a radial extent of the insert. The second zone includes a second plurality of cooling holes. The first plurality of cooling holes provide a first cooling density and the second plurality of cooling holes provide a second cooling density. The first cooling density is different from the second cooling density and the first plurality of cooling holes and the second plurality of cooling holes are configured to jet air towards the airfoil outer wall.
In a further example of the foregoing, the vane airfoil includes a transition zone between the first and second zones. The transition zone includes a gradual change in cooling density from the first density to the second density in a radial direction.
In a further example of any of the foregoing, the vane airfoil includes a third zone which is defined in a radial extent of the insert. The third zone includes a plurality of cooling holes. The plurality of cooling holes in the third zone have a third density. The third density being different from at least one of the first and second densities.
In a further example of any of the foregoing, the insert is a spar, and the spar is configured to provide structural support to the airfoil section.
In a further example of any of the foregoing, the airfoil section is a ceramic matrix composite.
A method of assembling a ceramic matrix composite vane airfoil according to an exemplary embodiment of this disclosure, among other possible things includes providing an insert. The insert includes a first zone defined in a first radial extent with respect to an airfoil component and corresponds to a first expected temperature of the airfoil component. A second zone is defined in a second radial extent with respect to the airfoil component and corresponds to a second expected temperature of the airfoil component. The first zone has a first plurality of cooling holes that provide a first cooling density which corresponds to the first expected temperature and the second zone has a second plurality of cooling holes that provide a second cooling density which corresponds to the second expected temperature. The first and second expected temperatures are different from one another. An insert is inserted into the airfoil component.
In a further example of the foregoing, at least some of the first and second pluralities of cooling holes are configured to jet air towards the airfoil component in a direction normal to a wall of the airfoil component.
In a further example of any of the foregoing, the first plurality of cooling holes are spaced apart from one another by a first distance, which provides the first cooling density. The second plurality of cooling holes are spaced apart from one another by a second distance, which provides the second cooling density. The first distance is different from the second distance.
In a further example of any of the foregoing, the first plurality of cooling holes have a first cumulative cross-sectional area, which provide the first cooling. The second plurality of cooling holes have a second cumulative cross-sectional area which provide the second cooling density. The first cumulative cross-sectional area is different from the second cumulative cross-sectional area.
In a further example of any of the foregoing, the insert is a spar, and the spar is configured to provide structural support to the airfoil section.
In a further example of any of the foregoing, a third zone defined in a third radial extent with respect to the airfoil component, and corresponds to a third expected temperature of the airfoil component. The third zone includes a third plurality of cooling holes that provide a third cooling density. The third cooling density being different from at least one of the first and second cooling densities.
In a further example of any of the foregoing, the insert includes at least one rib which extends in a radial direction on the insert.
Although the different examples have the specific components shown in the illustrations, embodiments of this invention are not limited to those particular combinations. It is possible to use some of the components or features from one of the examples in combination with features or components from another one of the examples.
These and other features disclosed herein can be best understood from the following specification and drawings, the following of which is a brief description.
The various features and advantages of the present disclosure will become apparent to those skilled in the art from the following detailed description. The drawings that accompany the detailed description can be briefly described as follows.
Although the different examples have the specific components shown in the illustrations, embodiments of this invention are not limited to those particular combinations. It is possible to use some of the components or features from one of the examples in combination with features or components from another one of the examples.
These and other features disclosed herein can be best understood from the following specification and drawings, the following of which is a brief description.
The exemplary engine 20 generally includes a low speed spool 30 and a high speed spool 32 mounted for rotation about an engine central longitudinal axis A relative to an engine static structure 36 via several bearing systems 38. Terms such as “axial,” “radial,” “circumferential,” and variations of these terms are made with reference to the engine central axis A. It should be understood that various bearing systems 38 at various locations may alternatively or additionally be provided, and the location of bearing systems 38 may be varied as appropriate to the application.
The low speed spool 30 generally includes an inner shaft 40 that interconnects, a first (or low) pressure compressor 44 and a first (or low) pressure turbine 46. The inner shaft 40 is connected to the fan 42 through a speed change mechanism, which in exemplary gas turbine engine 20 is illustrated as a geared architecture 48 to drive a fan 42 at a lower speed than the low speed spool 30. The high speed spool 32 includes an outer shaft 50 that interconnects a second (or high) pressure compressor 52 and a second (or high) pressure turbine 54. A combustor 56 is arranged in exemplary gas turbine 20 between the high pressure compressor 52 and the high pressure turbine 54. A mid-turbine frame 57 of the engine static structure 36 may be arranged generally between the high pressure turbine 54 and the low pressure turbine 46. The mid-turbine frame 57 further supports bearing systems 38 in the turbine section 28. The inner shaft 40 and the outer shaft 50 are concentric and rotate via bearing systems 38 about the engine central longitudinal axis A which is collinear with their longitudinal axes.
The core airflow is compressed by the low pressure compressor 44 then the high pressure compressor 52, mixed and burned with fuel in the combustor 56, then expanded over the high pressure turbine 54 and low pressure turbine 46. The mid-turbine frame 57 includes airfoils 59 which are in the core airflow path C. The turbines 46, 54 rotationally drive the respective low speed spool 30 and high speed spool 32 in response to the expansion. It will be appreciated that each of the positions of the fan section 22, compressor section 24, combustor section 26, turbine section 28, and fan drive gear system 48 may be varied. For example, gear system 48 may be located aft of the low pressure compressor, or aft of the combustor section 26 or even aft of turbine section 28, and fan 42 may be positioned forward or aft of the location of gear system 48.
The engine 20 in one example is a high-bypass geared aircraft engine. In a further example, the engine 20 bypass ratio is greater than about six (6), with an example embodiment being greater than about ten (10), the geared architecture 48 is an epicyclic gear train, such as a planetary gear system or other gear system, with a gear reduction ratio of greater than about 2.3 and the low pressure turbine 46 has a pressure ratio that is greater than about five. In one disclosed embodiment, the engine 20 bypass ratio is greater than about ten (10:1), the fan diameter is significantly larger than that of the low pressure compressor 44, and the low pressure turbine 46 has a pressure ratio that is greater than about five 5:1. Low pressure turbine 46 pressure ratio is pressure measured prior to inlet of low pressure turbine 46 as related to the pressure at the outlet of the low pressure turbine 46 prior to an exhaust nozzle. The geared architecture 48 may be an epicycle gear train, such as a planetary gear system or other gear system, with a gear reduction ratio of greater than about 2.3:1 and less than about 5:1. It should be understood, however, that the above parameters are only exemplary of one embodiment of a geared architecture engine and that the present invention is applicable to other gas turbine engines including direct drive turbofans.
A significant amount of thrust is provided by the bypass flow B due to the high bypass ratio. The fan section 22 of the engine 20 is designed for a particular flight condition—typically cruise at about 0.8 Mach and about 35,000 feet (10,668 meters). The flight condition of 0.8 Mach and 35,000 ft (10,668 meters), with the engine at its best fuel consumption—also known as “bucket cruise Thrust Specific Fuel Consumption (‘TSFC’)”—is the industry standard parameter of lbm of fuel being burned divided by lbf of thrust the engine produces at that minimum point. “Low fan pressure ratio” is the pressure ratio across the fan blade alone, without a Fan Exit Guide Vane (“FEGV”) system. The low fan pressure ratio as disclosed herein according to one non-limiting embodiment is less than about 1.45. “Low corrected fan tip speed” is the actual fan tip speed in ft/sec divided by an industry standard temperature correction of [(Tram ° R)/(518.7°R)]{circumflex over ( )}0.5. The “Low corrected fan tip speed” as disclosed herein according to one non-limiting embodiment is less than about 1150 ft/second (350.5 meters/second).
The vane airfoil 100 is formed of a ceramic material, such as a ceramic matrix composite (CMC) material. For example, the CMC includes a ceramic matrix and ceramic fibers disposed in the ceramic matrix. The ceramic matrix may be, but is not limited to, silicon carbide (SiC) and the ceramic fibers may be, but are not limited to, silicon carbide (SiC) fibers. The CMC is comprised of fiber plies that are arranged in a stacked configuration and formed to the desired geometry of the vane airfoil 100. For instance, the fiber plies may be layers or tapes that are laid-up one on top of the other to form the stacked configuration. The fiber plies may be woven or unidirectional, for example. At least a portion of the fiber plies are continuous through the platforms 102/104 and the airfoil section 106. In this regard, the vane airfoil 100 is a continuous body in that the fiber plies are uninterrupted through the platforms 102/104 and the airfoil section 106.
The vane airfoil 100 also includes an insert 112 that is disposed in the internal cavity 110. For instance, the insert 112 can be a spar, which provides structural support for the vane airfoil 100. In another example, the insert 112 is a baffle. In yet another example, the insert 112 is configured to act as both a spar and a baffle.
The insert 112 includes an insert wall 113 that defines and surrounds a central cavity. In one example, the insert wall 113 generally tracks the shape of the airfoil outer wall 108. The insert wall 113 includes a plurality of cooling holes 120. During operation of the engine 20, the outer face of the airfoil outer wall 108 is exposed to hot combustion gases. Cooling air such as bleed air from the compressor section 24 (
To assemble the vane airfoil 100, the insert 112 is inserted into the airfoil section 106 from an opening 111 shown in
The insert 112 may be provided as a pre-fabricated component for the insertion into the airfoil section 106. Alternatively, the insert 112 may be fabricated through a forming process as part of the assembly process of the vane airfoil 100. Furthermore, the insert 112 can be installed as above as part of an original fabrication of the vane airfoil 100, or as a repair or reconstruction of a vane airfoil 100 after a period of use in the engine 20.
As discussed above, during operation of the engine 20, the airfoil section 106 is exposed to hot combustion gases in the engine 20 and experiences a thermal gradient in the radial direction R (
In general, vanes formed of superalloys employ a thermal management strategy that involves cooling the vane as much as possible, to avoid exceeding the temperature limit of the superalloy and to limit effects of creep and fatigue. This paradigm dictates use of cooling schemes designed to maximize cooling effects. Ceramic materials, such as the CMC material discussed above, however, have high maximum use temperatures in comparison to metallic superalloys. Therefore, vanes formed of ceramic materials have no need to employ the same thermal management strategy that is used for superalloy vanes.
Additionally, ceramic materials have significantly lower thermal conductivity than superalloys and do not possess the same strength and ductility characteristics, making them more susceptible to distress from thermal gradients and the thermally induced stresses those cause. Therefore, although maximum cooling may be desirable for superalloy vanes, maximized cooling of a ceramic vane may exacerbate thermal gradients and thus be counter-productive to meeting durability goals. The cooling scheme represented in the examples described herein takes the approach of reducing thermal gradients, e.g., balances the temperature of various areas of the airfoil to a lower thermal gradient across the airfoil, to facilitate mitigation of thermal stresses on the ceramic.
The insert 112 includes cooling holes 120 that facilitate impingement cooling of the airfoil outer wall 108 by jetting cooling air towards the airfoil outer wall 108. Because of the thermal profiles discussed above, some areas of the airfoil outer wall 108 benefit from more cooling than other areas. Accordingly, the cooling holes are distributed throughout the insert to address the thermal profiles in order to balance the temperatures of various areas of the airfoil outer wall 108 to a lower thermal gradient across the airfoil outer wall 108. In other words, the distribution of cooling holes 120 corresponds to the thermal gradient such that more cooling is provided in areas of the airfoil section 106 that are expected to experience higher temperatures and less cooling is provided in areas of the airfoil section 106 that are expected to experience lower temperatures. To that end, a higher density of cooling holes 120 are provided in areas that require more cooling to balance the temperatures of various areas of the the airfoil outer wall 108 to a lower thermal gradient across the airfoil outer wall.
The amount of cooling, or “cooling density,” is related to a cumulative cross-sectional area of the cooling holes 120 in an incremental radial region of the airfoil section 106. The cumulative cross-sectional area is in turn related to the cooling hole 120 distribution density (number of cooling holes 120 in an area of the airfoil section 106, which is in turn related to the spacing between adjacent holes 120), the cumulative size of the cooling holes 120, or both. In other words, cooling density can be increased by increasing the cumulative size of the cooling holes 120, increasing the hole 120 distribution density (e.g., providing more cooling holes in an area by decreasing a distance d between cooling holes), or both. Conversely, cooling density can be decreased by decreasing the cumulative size of the cooling holes 120, decreasing the hole 120 distribution density, or both.
The cooling holes 120 can be circular in shape, or can have other shapes such as ovals or the like. The cooling holes 120 can all be the same size (e.g., have the same cross-sectional area) or have varying sizes. The cooling holes 120 can be punched into the material of the insert 112, which can be thin metal such as sheet metal. In general, the cooling holes 120 are configured to jet cooling air towards the airfoil outer wall 108 such that the cooling air impinges the airfoil outer wall 108 at an angle approximately normal to the airfoil outer wall 108. However, in some examples, the cooling holes 120 may jet the cooling air at a different angle with respect to the airfoil outer wall 108.
As shown in
Because each of the zones Z1, Z2, Z3 experience temperatures in a different temperature range, each of the zones Z1, Z2, Z3 requires a different cooling density. Accordingly, each of the zones Z1, Z2, Z3 have a different distributions of cooling holes 120.
The zone Z3 experiences relatively low temperatures, and has a relatively low cooling density. As discussed above, a relatively low cooling density can correspond to a relatively smaller hole 120 distribution density (e.g., relatively larger distance d3 between adjacent cooling holes 120). However, it should be understood that a relatively low cooling density can also correspond to a relatively smaller cumulative cross-sectional area of cooling holes 120 in zone Z3.
The zone Z2 experiences relatively high temperatures, and has a high cooling density. As discussed above, a relatively high cooling density can correspond to a relatively larger hole 120 distribution density (e.g., smaller distance d2 between adjacent cooling holes 120). In one example, the hole 120 distribution density in zone Z3 differs from the hole 120 distribution density in zone Z2 by at least 50%. In another example, the hole 120 distribution density in zone Z3 differs from the hole 120 distribution density in zone Z2 by at least 20%. In an third example, the hole 120 distribution density in zone Z3 differs from the hole 120 distribution density in zone Z2 by at least 10%.
However, it should be understood that a relatively high cooling density can also correspond to a relatively larger cumulative cross-sectional area of the cooling holes 120 in zone Z2. In one example, the cumulative cross-sectional area of the cooling holes 120 in zone Z3 differs from the cumulative cross-sectional area of the cooling holes 120 in zone Z2 by at least 50%. In another example, the cumulative cross-sectional area of the cooling holes 120 in zone Z3 differs from the cumulative cross-sectional area of the cooling holes 120 in zone Z2 by at least 20%. In another example, the cumulative cross-sectional area of the cooling holes 120 in zone Z3 differs from the cumulative cross-sectional area of the cooling holes 120 in zone Z2 by at least 10%.
The zone Z1 experiences mid-range temperatures, and has cooling density in between that of the zones Z2 and Z3, corresponding to either or both of a distance d2 between adjacent cooling holes between the distances d1 and d3, or a cumulative cross-sectional area of cooling holes 120 in between the cumulative cross-sectional area of cooling holes 120 in zones Z2 and Z3, in another example. The differing cooling densities in the zones Z1, Z2, Z3 of the insert 212 address hot spots due to the temperature profile along the airfoil section 106 in the radial direction (
In one example, there is a transition area between zones which provides a gradual change in cooling density between adjacent zones T1, T2, T3. As shown in
In the example of
In this example, the zones Z1 and Z3 include cooling holes 120 of varying sizes and shapes. For instance, zones Z1 and Z3 include relatively larger oval-shaped cooling holes 122 as well as relatively smaller circular cooling holes 120. However, it should be understood that other distributions/combinations of various cooling holes can be used. Regardless, the same principles regarding cooling hole density discussed above apply.
In the example of
Though the ribs 418 are shown in the example of
Although the different examples are illustrated as having specific components, the examples of this disclosure are not limited to those particular combinations. It is possible to use some of the components or features from any of the embodiments in combination with features or components from any of the other embodiments.
The foregoing description shall be interpreted as illustrative and not in any limiting sense. A worker of ordinary skill in the art would understand that certain modifications could come within the scope of this disclosure. For these reasons, the following claims should be studied to determine the true scope and content of this disclosure.
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