This application relates to a compressor housing for a radial compressor.
Compressors are utilized in any number of applications. One compressor application provides air to an air cycle machine on an aircraft. In known compressors, a compressor outlet housing has a volute, which provides a changing flow cross-sectional area downstream of a compressor impeller. The outlet further has a bearing support which mounts a bearing on the housing to support a shaft driving the impeller. An outer ledge provides a support surface for a portion of the impeller. The bearing support is connected to the outer ledge through a radially outwardly extending web.
The web is provided as a solid portion and the overall compressor housing is cast and then machined to a complex shape.
As might be appreciated, the outlet housing sees a number of challenges in operation and can be damaged.
A compressor outlet housing with a housing body has a volute and a radially inwardly extending wall extending from a radially inner surface of the volute. The radially inwardly extending wall extends inwardly to a ledge. A radially inwardly extending web extends to a bearing support. A fillet which will face an impeller when the compressor outlet housing is mounted in a compressor. The fillet connects the ledge to the web. An erosion resistant coating is formed on the fillet.
In addition, a compressor incorporating the compressor housing is disclosed as is a method of replacing a compressor outlet housing.
These and other features may be best understood from the following drawings and specification.
In this embodiment, the inlet 26 is connected to a RAM air inlet 19. This will supply air to the inlet 26 from a location outside of an aircraft incorporating the compressor 20. The air cycle machine 29 delivers air for use on that aircraft, such as providing air for an aircraft cabin.
As can be seen, the outlet housing 30 includes a bearing support 32, which supports an outer surface of the shaft 34 through bearings 35. A web 38 connects the bearing support 32 to a ledge 39. The ledge 39 connects the web 38 to a volute 36 through wall 58.
As shown, seal teeth 41 are formed on the back of the compressor impeller 22 and positioned adjacent a softer material on the compressor outlet housing 30. The seal teeth etch a groove into this portion of the housing to minimize leakage.
The compressor outlet housing 30 is formed of relatively soft aluminum. As shown in
Since the air entering the inlet 26 is from outside of the aircraft, it may contain impurities. The air hits the ledge 39 and web 38 at relatively high velocity. Thus, erosion damage can occur to the soft aluminum.
As shown, the coating does not need to coat the entirety of the ledge 39 nor the web 38. Instead, the coating is only over a portion of the ledge and web. In an embodiment, a radial distance d1 can be defined perpendicular to a central axis C of the bearing support 32, from an outer surface 204 of bearing support 32 to a radially inner end 251 of the ledge 39. A second distance d2 is also defined perpendicular to the axis C from the surface 204 to the radially innermost end 202 of the coating 200.
Another distance d3 is defined parallel to the axis C from a forward end 212 of the ledge 39 to a forward end 210 of the wall 58. Another distance d4 is defined from the axially forward end 220 of the coating 200 to the same end 210 of the wall 58. In embodiments, a ratio of d1 to d2 is between 1.1 and 2.0. In embodiments, it may be greater than 1.16. In embodiments, a ratio of d3 to d4 is between 1.1 and 2.0. Of course the coating can extend over the entire surface in some embodiments.
It is beneficial that the coating is not provided across the entirety of the web or the ledge, as the coating may well provide erosion resistance benefits, but may also comprise strength and thus its use may be minimized.
The coating may be tungsten carbide, or a similar hard coating. As one example, a hard aluminum coating may be utilized in combination with the otherwise soft aluminum of the body 119. The coatings can be applied by d-gun, HVOF or some similar method. In addition, a hard anodized coating or similar hard coating may be applied by chemical methods.
A compressor outlet housing 30 under this disclosure could be said to include a housing body 119 having a volute 36 and a radially inwardly extending wall 58 extending from a radially inner surface 17 of the volute. The radially inwardly extending wall 58 extends inwardly to a ledge 39, a radially inwardly extending web 38 extends to a bearing support 32. A fillet 149 will face an impeller 22 when the compressor outlet housing is mounted in a compressor. The fillet connects the ledge 39 to the web 38, and an erosion resistant coating 200 is formed at least on the fillet.
A method of repairing a compressor for use in an aircraft under this disclosure could be said to include the steps of removing an existing compressor outlet housing from a compressor having a compressor impeller and a compressor inlet connected to supply air to the compressor impeller. The compressor inlet is to be connected to a source of RAM air on an aircraft. The compressor has an electric motor for driving the compressor impeller, and a shaft driven by the electric motor to rotate the compressor impeller. The compressor impeller includes seal teeth. The method further includes the steps of replacing the existing compressor outlet housing with a replacement compressor outlet housing. The replacement compressor outlet housing has a housing body having a volute and a radially inwardly extending wall extending from a radially inner surface of said volute. The radially inwardly extending wall extending inwardly to a ledge. A radially inwardly extending web extends to a bearing support. A fillet faces the compressor impeller. The fillet connects the ledge to the web. An erosion resistant coating being formed on the fillet.
Although an embodiment of this invention has been disclosed, a worker of ordinary skill in this art would recognize that certain modifications would come within the scope of this disclosure. For that reason, the following claims should be studied to determine the true scope and content of this disclosure.