Patent Application
20120087803
This invention relates generally to gas turbine airfoil technology and, more specifically, to film cooling of the platform portion of an airfoil.
Film cooling holes are typically drilled into the platform portion of a gas turbine airfoil using a traditional straight or linear drill bit, oriented at a uniform shallow angle of approximately 30° relative to the surface of the platform. Holes drilled at an angle in excess of 30° will likely result in degraded film cooling performance. This constraint can lead to difficulty when attempting to drill into an internal platform cavity. For example, when worst-case casting core float and positional tolerances are considered, the edge of the drill bit may partially or completely miss the target cavity and continue on into the bucket shank or root portion. To alleviate the problem, the hole angle must be increased which, as already noted, has negative performance implications, or the hole must be moved closer to the slash face of the airfoil platform. Positioning the hole closer to the slash face, however, may limit part life by reducing the area benefited by film cooling and by introducing stress concentrations in an already life-challenged region.
It would therefore be desirable to develop a technique that maintains the preferred film cooling hole angle but that eliminates problems relating to traditional manufacturing process capability.
In accordance with an exemplary but nonlimiting embodiment, the present invention provides a turbine bucket comprising an airfoil portion at one end thereof; a root portion at an opposite end thereof; a platform portion between the airfoil portion and the root portion; at least one internal cavity within or radially inward of the platform portion having at least one film cooling hole extending between the at least one internal cavity and an external surface of the platform portion, the at least one film cooling hole being curved along a length dimension of the at least one film cooling hole.
In another aspect, the invention relates to a turbine component comprising an external surface adapted to be cooled by film cooling air; an internal cavity within the turbine component adapted to supply film cooling air to the external surface; and at least one film cooling hole extending substantially radially between the internal cavity and the external surface, the at least one film cooling hole being curved along a length dimension of the at least one film cooling hole, wherein the at least one film cooling hole opens along a surface of the external surface at an angle of less than about 30° relative to the external surface, and wherein the at least one film cooling hole opens along a surface of the internal cavity at an angle greater than about 30° relative to the surface of the internal cavity.
In still another aspect, the invention relates a method of forming a film cooling hole in a turbine bucket platform connecting an external surface of the platform to an internal cavity within or radially inward of the platform comprising (a) locating a film cooling hole exit point on an exterior surface of the platform and a film cooling hole entry point opening into the internal cavity; and (b) drilling the film cooling hole to follow a curved path between the film cooling hole exit point and the film cooling hole entry point.
The invention will now be described in greater detail in connection with the drawings identified below.
Referring initially to
With reference now to
The present invention relates to an improved technique for forming the platform film cooling holes 20, but it is to be understood that the invention is not limited to any particular cooling circuit design for either the platform or the airfoil (or any other component), and is applicable in any situation where film cooling holes are employed and where the benefits of curved film cooling holes may be realized.
With continued reference to
In accordance with an exemplary but non-limiting embodiment of the invention, and with reference now to
In the exemplary embodiment, the curved film cooling holes 30 may be drilled utilizing, for example, any conventional precision and high-speed wire EDM machines. Suitable EDM machines are available from, for example, Aerospace Techniques of Middletown, Conn., but others are available as well.
Other methods to drill curved holes include STEM (shaped-tube electrochemical machining), in which a curved electrode is rotated into the part to create a curved hole typically of constant radius but also of non-constant radii of curvature. Other ECM (electrochemical machining) or combination of methods could be used to form the hole in either a single or multiple processes.
It will be appreciated that many such film cooling holes 30 may be formed in any desired pattern to effectively film cool the bucket platform 16. The holes 30 may have diameters of about 0.03″, but the diameter may vary depending on specific applications.
in an exemplary embodiment, the platform end of the hole (or hole exit point) and the internal cavity end of the hole (or hole entry point) are determined and then the EDM or ECM machine is utilized to drill the hole at a uniform or non-uniform radius of curvature to insure that the hole or passage terminates well within the cavity 18 (or 22).
As indicated above, the invention is applicable in the drilling of cooling holes in the airfoil platform, the airfoil itself, or in any other component where film cooling hole configuration and location are critical.
While the invention has been described in connection with what is presently considered to be the most practical and preferred embodiment, it is to be understood that the invention is not to be limited to the disclosed embodiment, but on the contrary, is intended to cover various modifications and equivalent arrangements included within the spirit and scope of the appended claims.
