This application relates generally to gas turbine engines and, more particularly, to methods and apparatus for cooling gas turbine engine rotor blades.
At least some known rotor assemblies include at least one row of circumferentially-spaced rotor blades. Each rotor blade includes an airfoil that includes a pressure side, and a suction side connected together at leading and trailing edges. Each airfoil extends radially outward from a rotor blade platform to a tip, and also includes a dovetail that extends radially inward from a shank extending between the platform and the dovetail. The dovetail is used to couple the rotor blade within the rotor assembly to a rotor disk or spool. At least some known rotor blades are hollow such that an internal cooling cavity is defined at least partially by the airfoil, through the platform, the shank, and the dovetail.
During operation, because the airfoil portion of each blade is exposed to higher temperatures than the dovetail portion, temperature gradients may develop at the interface between the airfoil and the platform, and/or between the shank and the platform. Over time, thermal strain generated by such temperature gradients may induce compressive thermal stresses to the blade platform. Moreover, over time, the increased operating temperature of the platform may cause platform oxidation, platform cracking, and/or platform creep deflection, which may shorten the useful life of the rotor blade.
To facilitate reducing the effects of the high temperatures in the platform region, shank cavity air and/or a mixture of blade cooling air and shank cavity air is introduced into a region below the platform region to facilitate cooling the platform. However, in at least some known turbines, the shank cavity air is significantly warmer than the blade cooling air. Moreover, because the platform cooling holes are not accessible to each region of the platform, the cooling air may not be provided uniformly to all regions of the platform to facilitate reducing an operating temperature of the platform region.
In one aspect, a method for fabricating a turbine rotor blade is provided. The method includes casting a turbine rotor blade including a dovetail, a platform having an outer surface, an inner surface, and a cast-in plenum defined between the outer surface and the inner surface, and an airfoil, and forming a plurality of openings between the platform inner surface and the platform outer surface to facilitate cooling an exterior surface of the platform.
In another aspect, a turbine rotor blade is provided. The turbine rotor blade includes a dovetail, a platform coupled to the dovetail, wherein the platform includes a cast-in plenum formed within the platform, an airfoil coupled to the platform, and a cooling source coupled in flow communication to the cast-in plenum.
In a further aspect, a gas turbine engine is provided. The gas turbine engine includes a turbine rotor, and a plurality of circumferentially-spaced rotor blades coupled to the turbine rotor, wherein each rotor blade includes a dovetail, a platform coupled to the dovetail, wherein the platform includes a cast-in plenum formed within the platform, an airfoil coupled to the platform, and a cooling source coupled in flow communication to the cast-in plenum.
In operation, air flows through low-pressure compressor 12 and compressed air is supplied to high-pressure compressor 14. Highly compressed air is delivered to combustor 16. Combustion gases from combustor 16 propel turbines 18 and 20. High pressure turbine 18 rotates second shaft 28 and high pressure compressor 14, while low pressure turbine 20 rotates first shaft 26 and low pressure compressor 12 about axis 32. During some engine operations, a high pressure turbine blade may be subjected to a relatively large thermal gradient through the platform, i.e. (hot on top, cool on the bottom) causing relatively high tensile stresses at a trailing edge root of the airfoil which may result in a mechanical failure of the high pressure turbine blade. Improved platform cooling facilitates reducing the thermal gradient and therefore reduces the trailing edge stresses. Rotor blades may also experience concave platform cracking and bowing from creep deformation due to the high platform temperatures. Improved platform cooling described herein facilitates reducing these distress modes as well.
Each airfoil 60 includes a first sidewall 70 and a second sidewall 72. First sidewall 70 is convex and defines a suction side of airfoil 60, and second sidewall 72 is concave and defines a pressure side of airfoil 60. Sidewalls 70 and 72 are joined together at a leading edge 74 and at an axially-spaced trailing edge 76 of airfoil 60. More specifically, airfoil trailing edge 76 is spaced chord-wise and downstream from airfoil leading edge 74.
First and second sidewalls 70 and 72, respectively, extend longitudinally or radially outward in span from a blade root 78 positioned adjacent platform 62, to an airfoil tip 80. Airfoil tip 80 defines a radially outer boundary of an internal cooling chamber (not shown) that is defined within blades 50. More specifically, the internal cooling chamber is bounded within airfoil 60 between sidewalls 70 and 72, and extends through platform 62 and through shank 64 and into dovetail 66 to facilitate cooling airfoil 60.
Platform 62 extends between airfoil 60 and shank 64 such that each airfoil 60 extends radially outward from each respective platform 62. Shank 64 extends radially inwardly from platform 62 to dovetail 66, and dovetail 66 extends radially inwardly from shank 64 to facilitate securing rotor blades 50 to rotor disk 30. Platform 62 also includes an upstream side or skirt 90 and a downstream side or skirt 92 that are connected together with a pressure-side edge 94 and an opposite suction-side edge 96.
Cast-in plenum 100 includes a first plenum portion 106, a second plenum portion 108, and a third plenum portion 110 coupled in flow communication with plenums 106 and 108. First plenum portion 106 includes an upper surface 120, a lower surface 122, a first side 124, and a second side 126 that are each defined by inner surface 104. In the exemplary embodiment, first side 124 has a generally concave shape that substantially mirrors a contour of second sidewall 72. Second plenum portion 108 includes an upper surface 130, a lower surface 132, a first side 134, and a second side 136 each defined by inner surface 104. In the exemplary embodiment, first side 134 has a generally convex shape that substantially mirrors a contour of first sidewall 70. In the exemplary embodiment, platform 62 includes a substantially solid portion 140 that extends between first plenum portion 106, second plenum portion 108, and third plenum portion 110 such that portion 140 is bounded by first plenum portion 106, second plenum portion 108, and third plenum portion 110. More specifically, turbine rotor blade 50 is cored between first plenum portion 106, second plenum portion 108, and third plenum portion 110 such that a substantially solid base 140 is defined between airfoil 60, platform 62, and shank 64. Accordingly, fabricating rotor blade 50 such that cast-in plenum 100 is contained entirely within platform 62 facilitates increasing a structural integrity of turbine rotor blade 50.
Turbine rotor blade 50 also includes a channel 150 that extends from a lower surface 152 of dovetail 66 to cast-in plenum 100. More specifically, channel 150 includes an opening 154 that extends through shank 64 such that lower surface 152 is coupled in flow communication with cast-in plenum 100. Channel 150 includes a first end 156 and a second end 158. Second end 158 is coupled in flow communication to third plenum portion 110.
Turbine rotor blade 50 also include a plurality of openings 160 formed in flow communication with cast-in plenum 100 and extending between cast-in plenum 100 and platform outer surface 102. Openings 160 facilitate cooling platform 62. In the exemplary embodiment, openings 160 extend between cast-in plenum 100 and platform outer surface 102. In another embodiment, openings 160 extend between cast-in plenum 100 and a side 162 of platform outer surface 102. In yet another embodiment, openings 160 extend between cast-in plenum 100 and a lower portion 164 of platform outer surface 102. In the exemplary embodiment, openings 160 are sized to enable a predetermined amount of cooling airflow to be discharged therethrough to facilitate cooling platform 62.
During fabrication of cast-in plenum 100, a core (not shown) is cast into turbine blade 50. The core is fabricated by injecting a liquid ceramic and graphite slurry into a core die (not shown). The slurry is heated to form a solid ceramic plenum core. The core is suspended in an turbine blade die (not shown) and hot wax is injected into the turbine blade die to surround the ceramic core. The hot wax solidifies and forms a turbine blade with the ceramic core suspended in the blade platform.
The wax turbine blade with the ceramic core is then dipped in a ceramic slurry and allowed to dry. This procedure is repeated several times such that a shell is formed over the wax turbine blade. The wax is then melted out of the shell leaving a mold with a core suspended inside, and into which molten metal is poured. After the metal has solidified the shell is broken away and the core removed.
During engine operation, cooling air entering channel first end 156 is channeled through channel 150 and discharged into cast-in plenum 100. The cooling air is then channeled from cast-in plenum 100 through openings 160 and around platform outer surface 102 to facilitate reducing an operating temperature of platform 62. Moreover, the cooling air discharged from openings 160 facilitates reducing thermal strains induced to platform 62. Openings 160 are selectively positioned around an outer periphery 170 of platform 62 to facilitate compressor cooling air being channeled towards selected areas of platform 62 to facilitate optimizing the cooling of platform 62. Accordingly, when rotor blades 50 are coupled within the rotor assembly, channel 150 enables compressor discharge air to flow into cast-in plenum 100 and through openings 160 to facilitate reducing an operating temperature of platform 62.
Turbine rotor blade 50 also includes a first channel 250 that extends from a lower surface 252 of dovetail 66 to first plenum portion 206 and a second channel 251 that extends from lower surface 252 of dovetail 66 to second plenum portion 208. In one embodiment, first and second channels 250, 251 are formed unitarily. In another embodiment, first and second channels 250, 251 are formed as separate components such that first channel 250 channels cooling air to first plenum portion 206 and second channel 251 channels cooling air to second plenum portion 208. In the exemplary embodiment, first and second channels 250, 251 are positioned along at least one of upstream side or skirt 90 and downstream side or skirt 92. More specifically, channel 250 includes an opening 254 that extends through shank 64 such that lower surface 252 is coupled in flow communication with first plenum portion 206 and channel 251 includes an opening 255 that extends through shank 64 such that lower surface 252 is coupled in flow communication with second plenum portion 208.
During engine operation, cooling air entering a first channel 250 and second channel 251 are channeled through channels 250 and 251 respectively and discharged into first plenum portion 206 and second plenum portion 208 respectively. The cooling air is then channeled from each respective plenum portion through openings 260 and around platform outer surface 102 to facilitate reducing an operating temperature of platform 62. Moreover, the cooling air discharged from openings 260 facilitates reducing thermal strains induced to platform 62. Openings 260 are selectively positioned around an outer periphery 170 of platform 62 to facilitate compressor cooling air being channeled towards selected areas of platform 62 to facilitate optimizing the cooling of platform 62. Accordingly, when rotor blades 50 are coupled within the rotor assembly, channels 250 and 251 enable compressor discharge air to flow into cast-in plenums 206 and 208 and through openings 260 to facilitate reducing an operating temperature of platform 62.
Turbine rotor blade 50 also includes a first channel 350 that extends from a lower surface 352 of dovetail 66 to first plenum portion 306 and a second channel 351 that extends from lower surface 352 of dovetail 66 to second plenum portion 308. In the exemplary embodiment, first and second channels 350, 351 are formed as separate components such that first channel 350 channels cooling air to first plenum portion 306 and second channel 351 channels cooling air to second plenum portion 308. In the exemplary embodiment, first channel 350 is positioned along at least one of upstream side or skirt 90 and downstream side or skirt 92, and second channel 351 is positioned along at least one of upstream side or skirt 90 and downstream side or skirt 92 opposite first channel 350. More specifically, channel 350 includes an opening 354 that extends through shank 64 such that lower surface 352 is coupled in flow communication with first plenum portion 306, and second channel 351 includes an opening 355 that extends through shank 64 such that lower surface 352 is coupled in flow communication with second plenum portion 308.
During engine operation, cooling air entering a first channel 350 and second channel 351 are channeled through channels 350 and 351 respectively and discharged into first plenum portion 306 and second plenum portion 308 respectively. The cooling air is then channeled from each respective plenum portion through openings 360 and around platform outer surface 302 to facilitate reducing an operating temperature of platform 62. Moreover, the cooling air discharged from openings 360 facilitates reducing thermal strains induced to platform 62. Openings 360 are selectively positioned around an outer periphery 170 of platform 62 to facilitate compressor cooling air being channeled towards selected areas of platform 62 to facilitate optimizing the cooling of platform 62. Accordingly, when rotor blades 50 are coupled within the rotor assembly, channels 350 and 351 enable compressor discharge air to flow into cast-in plenums 306 and 308 and through openings 360 to facilitate reducing an operating temperature of platform 62.
The above-described rotor blades provide a cost-effective and reliable method for supplying cooling air to facilitate reducing an operating temperature of the rotor blade platform. More specifically, through cooling flow, thermal stresses induced within the platform, and the operating temperature of the platform is facilitated to be reduced. Accordingly, platform oxidation, platform cracking, and platform creep deflection is also facilitated to be reduced. As a result, the rotor blade cooling cast-in-plenums facilitate extending a useful life of the rotor blades and improving the operating efficiency of the gas turbine engine in a cost-effective and reliable manner. Moreover, the method and apparatus described herein facilitate stabilizing platform hole cooling flow levels because the air is provided directly to the cast-in plenum via a dedicated channel, rather than relying on secondary airflows and/or leakages to facilitate cooling platform 62. Accordingly, the method and apparatus described herein facilitates eliminating the need for fabricating shank holes in the rotor blade.
Exemplary embodiments of rotor blades and rotor assemblies are described above in detail. The rotor blades are not limited to the specific embodiments described herein, but rather, components of each rotor blade may be utilized independently and separately from other components described herein. For example, each rotor blade cooling circuit component can also be used in combination with other rotor blades, and is not limited to practice with only rotor blade 50 as described herein. Rather, the present invention can be implemented and utilized in connection with many other blade and cooling circuit configurations. For example, the methods and apparatus can be equally applied to rotor vanes such as, but not limited to an HPT vanes.
While the invention has been described in terms of various specific embodiments, those skilled in the art will recognize that the invention can be practiced with modification within the spirit and scope of the claims.
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Number | Date | Country | |
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