The invention relates to gas turbine engine rotating blades. More particularly, the invention relates to gas turbine engine blades having an increased airfoil outer wall thickness zone proximate the hub and trailing edge (TE), which reduces blade-cracking propensity and enhances blade service life.
Repetitive or cyclic loading of gas turbine engine blades during service operation may induce metal fatigue cracks in the blade substrate. Commonly recognized fatigue mechanisms are thermo-mechanical fatigue (TMF), high-cycle fatigue (HCF) and low-cycle fatigue (LCF). TMF thermal strain is attributable to blade thermal expansion and contraction experienced during large temperature changes, such as induced during engine powering on or off or changes in engine load. TMF mechanical strains are associated with centrifugal loads during engine speed changes or output load, which are cumulative with the thermally induced strains. HCF is attributed to low-amplitude, high-frequency strains induced by blade flexure during engine operation, which can induce crack propagation during ongoing engine operation. LCF is characterized by high-amplitude, low-frequency plastic strains in regions of stress concentration.
One observed blade substrate zone that is susceptible to LCF/TMF cracking is often in a region proximate the blade airfoil trailing edge and blade hub platform, and associated pedestals that are formed within the airfoil interior, which bridge opposed interior wall surfaces. A crack initiating at one location within this region has propensity to grow or propagate as the blade flexes cyclically during engine shaft rotation under HCF operational conditions. Conventional wisdom for blade design is to minimize turbine engine blade airfoil outer wall thickness, in order to minimize rotating mass and thermal mass TMF influences. Under such conventional wisdom, thin airfoil wall thickness also reduces airfoil cross section, which is thought to enhance aerodynamic efficiency. Past proposed solutions to reduce crack propensity in the region proximate the blade airfoil trailing edge and blade hub platform has been to incorporate a constant or compound curve hub fillet around all or part of the airfoil wall and blade platform junction, while maintaining a relatively constant airfoil wall thickness along the entire trailing edge from hub to blade tip.
Despite conventional design wisdom to minimize turbine engine blade trailing edge (TE) thickness, in order to reduce rotating mass-induced cyclic fatigue and increase aerodynamic efficiency, local thickening of the airfoil outer or side wall zone in the region proximate the TE and hub actually reduces, rather than increases, peak stress at previously observed crack locations around the hub to airfoil wall TE region. Furthermore, increasing local thickening of the airfoil wall zone along the TE from the hub to approximately eight to ten percent (8-10%) of the airfoil stand length, which in some embodiments encompass typically the first five to eight TE pedestals, reduces likelihood of cracks at pedestal/side wall junction regions. Local thickening of the TE reduces the peak stress at the pedestal outer or side wall location and crack formation, which in turn enhances component service life. In cast turbine blades, the TE airfoil wall thickening zone not only reduces stress, but also enhances the casting alloy grain structure in a way to improve creep ductility, by changing the relative rates of solidification of the airfoil TE and the adjacent blade platform mass. The thickened TE zone drives the solidification relative rates in a way that enhances alloy grain structure and ductility, which beneficially retards crack propagation rate.
Exemplary gas turbine engine blade embodiments described herein increase airfoil wall thickness in a zone that is proximate the trailing edge (TE) and hub by forty to sixty percent (40-60%) greater than the comparable greatest wall thickness anywhere else along the trailing edge from outboard that zone all the way to the blade tip. Some embodiments also incorporate pedestals with compound curve fillets in the increased wall thickness zone. While increasing airfoil wall thickness anywhere on a turbine blade is counterintuitive to known conventional blade design, it has been found to reduce blade cracking propensity in the same zone, enhancing service life, with no significant change in blade aerodynamic efficiency.
Exemplary embodiments of the invention feature a turbine engine blade, including a hub with a blade platform and an elongated airfoil portion. The airfoil has an outer wall, also called a side wall, delimiting a pressure side, a suction side, a leading edge, and a trailing edge on its exterior surface. The airfoil outer wall delimits an airfoil interior on its interior surface. Airfoil outer wall thickness is established between the respective interior and exterior surfaces. A proximal end of the outer wall is coupled to the blade platform from the leading edge to the trailing edge. Correspondingly, a distal end of the outer wall defines a blade tip. The airfoil defines a span dimension (also referred to as a stand length, or height) between its proximal and distal ends. The blade has a hub fillet circumscribing and joined to the airfoil outer wall exterior surface at the proximal end, which is also joined to the blade platform. In a turbine blade casting, the hub fillet is integrally cast with the airfoil outer wall and the blade platform, adding extra material thickness to the blade region where the exterior surface of the hub outer wall and the blade platform converge. In the increased thickness zone, which has a zone proximal end adjoining the blade platform and a zone distal end, the zone's proximal end outer wall thickness, excluding adjoining hub fillet thickness, is approximately forty to sixty percent (40-60%) greater along the trailing edge for approximately eight to ten percent (8-10%) of total airfoil span than the comparable greatest wall thickness anywhere else along the trailing edge from outboard that zone all the way to the distal tip. The corresponding outer wall thickness in the increased thickness zone transitions from the thicker region proximate the hub to that of the outboard thinner region that is proximate the tip.
Other exemplary embodiments of the invention feature a turbine engine blade, including a hub with a blade platform and an elongated airfoil portion. The airfoil has an outer wall, which is also referred to as a side wall, delimiting a pressure side, a suction side, a leading edge, and a trailing edge on its exterior surface. The airfoil outer wall delimits an airfoil interior on its interior surface. Airfoil outer wall thickness is defined between its respective interior and exterior surfaces. A proximal end of the outer wall is coupled to the blade platform from the leading edge to the trailing edge. Correspondingly, a distal end of the outer wall defines a blade tip. The airfoil defines a span dimension (also referred to as a stand length, or height) between its proximal and distal ends. The blade has a hub fillet circumscribing and joined to the airfoil outer wall exterior surface at the proximal end, which is also joined to the blade platform. In a turbine blade casting, the hub fillet is integrally cast with the airfoil outer wall and the blade platform, adding extra material thickness to the blade region where the exterior surface of the hub outer wall and the blade platform converge. In this embodiment, a plurality of elongated pedestals spans the airfoil interior, and is oriented along the airfoil stand length between the proximal and distal ends. The respective pedestals have an elongated cross section, defining a major axis that is generally perpendicular to stand length dimension of the airfoil, and a minor axis that is generally parallel with the airfoil stand length dimension. First and second ends of each respective pedestal is coupled to respective corresponding opposed interior surfaces of the outer wall pressure and suction sides, proximate the trailing edge, by pedestal fillets. In the increased outer wall thickness zone, the airfoil proximal end outer wall thickness, excluding adjoining hub fillet thickness, is approximately forty to sixty percent (40-60%) greater along the trailing edge for approximately eight to ten percent (8-10%) of total airfoil span than the comparable greatest wall thickness anywhere else along the trailing edge from outboard that zone all the way to the blade tip. The corresponding outer wall thickness in the increased thickness zone transitions from the thicker region proximate the hub to that of the outboard thinner region that is proximate the tip.
The respective features of the exemplary embodiments of the invention that are described herein may be applied jointly or severally in any combination or sub-combination.
The exemplary embodiments of the invention are further described in the following detailed description in conjunction with the accompanying drawings, in which:
To facilitate understanding, identical reference numerals have been used, where possible, to designate identical elements that are common to the figures. Any reference designation “XX/YY” indicated that the associated lead line is directed to both of the elements XX and YY. The figures are not drawn to scale.
Exemplary embodiments of the invention are utilized in gas turbine engine rotating blades. More particularly, such blades having an increased airfoil outer wall or side wall thickness zone proximate the hub and trailing edge (TE), which reduces blade cracking propensity and enhances blade service life. Airfoil TE wall thickness in this zone proximate the hub is forty to sixty percent (40-60%) greater than the comparable greatest wall thickness anywhere else along the trailing edge from outboard that zone all the way to the blade tip. In many embodiments, the TE outer wall thickness proximate the blade tip and outboard or above the zone remains constant or tapers to reduced thickness along the span or stand length to the tip. The increased thickness zone generally comprises eight to ten percent (8-10%) of the total blade stand height. In some embodiments, the corresponding outer wall thickness in the increased thickness zone transitions from the thicker region proximate the hub to that of the outboard thinner region that is proximate the tip for an additional five to seven percent (5-7%) of the total blade span or stand height. In some embodiments, the increased thickness zone incorporates the first five to eight TE pedestals. In some embodiments, such pedestals also incorporate compound curve fillets in the increased outer wall thickness zone or in any other desired zone. The increased outer wall or side wall thickness zone reduces blade cracking propensity and enhances service life.
The increased outer wall thickness zone invention embodiments are adaptable to upgrade existing blade designs, by incorporating a thicker airfoil outer wall or side wall in the TE at the hub, and modifying the existing hub fillet profile. The thicker trailing edge zone reduces blade stress, which improves its LCF life. In cast superalloy blades embodiments, the thicker outer wall zone modification not only reduces the average stress, due to the larger bearing area, but also creates simultaneously a more desirable grain structure at this location by changing the liquid metal solidification rate. The thicker casting wall in the hub/TE zone advantageously also enhances grain size. Large grains reduce the number of inter granular zones that might otherwise be susceptible to crack formation. The resulting TE wall thickness zone exhibits better creep ductility properties that further retard concentrated creep stress induced crack initiation and propagation.
Some embodiments of the invention incorporate larger pedestal compound fillets, which additionally reduce stress concentration in the lower TE zone proximate the hub, and raise the fatigue life of the blade. In some embodiments, the pedestal fillet incorporates a compound fillet, in order to maintain sufficient interior cavity volume in the blade airfoil for delivery of blade coolant to the trailing edge, while still maximizing stress concentration reduction.
As shown in
Referring to
Referring to
As previously noted, the airfoil 26 has an increased airfoil side wall or outer wall 36 thickness zone 50, excluding any adjoining hub fillet 46 thickness, which is also proximate the trailing edge 30. As shown in
Relative differences in airfoil outer wall or side wall thickness zone 50 along the trailing edge 30 are defined as follows, referring to the blade cross section of
In the embodiment of
Beneficially an existing blade design can be upgraded to a design incorporating the present invention by reconfiguring the blade trailing edge 30 proximate its hub to include the increased thickness zone 50, along with an incorporated transition thickness zone that merges with the existing blade distal trailing edge 30 thickness profile above or outboard of that zone. Pedestals constructed in accordance with the embodiments herein can be included in the increased thickness zone 50.
Increased trailing edge outer wall thickness in the zone 50 directly changes the relative casting solidification rates of the airfoil trailing edge 30 and the blade platform 24 mass in a direction that results in improved grain structure from the casting process. This improvement increases the concentrated rupture capability as confirmed by microstructural evaluations and elevated temperature concentrated creep rupture testing. These comparisons of a thickened TE 30 blade casting, with the zone 50, as compared to nominal thickness blade castings, confirmed the effects on concentrated rupture capability. Grain size affects the crack initiation and propagation in the concentrated stress areas. Increased airfoil outer wall 38 thickness in the zone 50 directly influences these formations in a positive direction, by changing relative solidification rate to reduce the formation of fine grains that result in reduced ductility and corresponding concentrated creep rupture capability.
Although various embodiments that incorporate the invention have been shown and described in detail herein, others can readily devise many other varied embodiments that still incorporate the claimed invention. The invention is not limited in its application to the exemplary embodiment details of construction and the arrangement of components set forth in the description or illustrated in the drawings. The invention is capable of other embodiments and of being practiced or of being carried out in various ways. in addition, it is to be understood that the phraseology and terminology used herein is for the purpose of description and should not be regarded as limiting. The use of “including,” “comprising,” or “having” and variations thereof herein is meant to encompass the items listed thereafter and equivalents thereof as well as additional items. Unless specified or limited otherwise, the terms “mounted”, “connected”, “supported”, and “coupled” and variations thereof are used broadly and encompass direct and indirect mountings, connections, supports, and couplings.
This application claims the benefit of priority under U.S. Provisional Application No. 62/190,459, filed Jul. 9, 2015, and entitled “Blade for Gas Turbine Engine”, which is incorporated by reference herein.
Number | Date | Country | |
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62190459 | Jul 2015 | US |