Patent Application
20100104426
Aspects of the invention relate in general to turbine engines and, more particularly, to ring seals in the turbine section of a turbine engine.
Between the rows of vanes 18, a ring seal 34 can be attached to the inner peripheral surface 30 of the vane carrier 28. The ring seal 34 is a stationary component that acts as a hot gas path guide between the rows of vanes 18 at the locations of the rotating blades 20. The ring seal 34 is commonly formed by a plurality of metal ring segments. The ring segments can be attached either directly to the vane carrier 28 or indirectly such as by attaching to metal isolation rings (not shown) that attach to the vane carrier 28. Each ring seal 34 can substantially surround a row of blades 20 such that the tips 26 of the rotating blades 20 are in close proximity to the ring seal 34.
During engine operation, high temperature, high velocity gases flow through the rows of vanes 18 and blades 20 in the turbine section 16. The ring seals 34 are exposed to these gases as well. Some metal ring seals 34 must be cooled in order to withstand the high temperature. In many engine designs, demands to improve engine performance have been met in part by increasing engine firing temperatures. Consequently, the ring seals 34 require greater cooling to keep the temperature of the ring seals 34 within the critical metal temperature limit. In the past, the ring seals 34 have been coated with thermal barrier coatings to minimize the amount of cooling required. However, even with a thermal barrier coating, the ring seal 34 must still be actively cooled to prevent the ring seal 34 from overheating and burning up. Such active cooling systems are usually complicated and costly. Further, the use of greater amounts of air to cool the ring seals 34 detracts from the use of air for other purposes in the engine.
As an alternative, the ring seals 34 could be made of ceramic matrix composites (CMC), which have higher temperature capabilities than metal alloys. By utilizing such materials, cooling air can be reduced, which has a direct impact on engine performance, emissions control and operating economics. However, CMC materials have their own drawbacks. For instance, CMC materials (oxide and non-oxide based) have anisotropic strength properties. The interlaminar tensile strength (the “through thickness” tensile strength) of CMC can be substantially less than the in-plane strength. Anisotropic shrinkage of the matrix and the fibers can result in delamination defects, particularly in small radius corners and tightly-curved sections, which can further reduce the interlaminar tensile strength of the material.
Thus, there is a need for a CMC ring seal construction that can minimize the limiting aspects of CMC material properties and manufacturing constraints.
Aspects of the invention are directed to a turbine engine ring seal segment. The ring seal segment includes a first channel and a second channel. Each of the channels is shaped so as to form an extension that transitions into a forward span and an aft span. The forward and aft spans are opposite each other and extend at an angle from the extension in a radially outward direction. Each of the channels can have an outer surface and an inner surface, which can be radially inwardly concave. The inner surface of the extension of the first and/or second channel can be coated with a thermal insulating material. In one embodiment, the thickness of the thermal insulating material can decrease along the extension in the axial direction.
Each channel can include a transition region between each of the forward and aft spans and the axial extension. The first and/or second channels can be preloaded so that at least a portion of each transition region is placed in compression in the through thickness direction.
The first and second channels are detachably coupled such that the aft span of the first channel substantially abuts the forward span of the second channel. As a result, an axial interface is defined. In one embodiment, the first and second channels can be detachably coupled by a plurality of fasteners that operatively engage the aft span of the first channel and the forward span of the second channel. The axial interface can be sealed. To that end, a seal and/or a bonding material can operatively engage the aft span of the first channel and the forward span of the second channel.
The first and second channels can be made of any suitable material. For instance, the first channel and/or the second channel can be made of ceramic matrix composite. However, one or both of the channels can be made of a material other than a ceramic matrix composite. Further, the first and second channels can be made of different materials.
In another respect, aspects of the invention relate to a turbine engine ring seal system. The system includes a turbine stationary support structure and a first ring seal segment operatively connected to the turbine stationary support structure, by, for example, a plurality of fasteners. The first ring seal segment includes a first channel and a separate second channel. Each of the channels can have an inner surface, which can be radially inwardly concave, and an outer surface.
Further, each of the first and second channels is shaped so as to form an extension that transitions into a forward span and an aft span. The forward and aft spans are opposite each other and extend at an angle from the extension in a radially outward direction. At least the inner surface of the extension of one or both of the channels can be coated with a thermal insulating material.
Each channel can include a transition region between the forward span and the axial extension as well as between the aft span and the axial extension. The first channel and/or the second channel can be preloaded so that at least a portion of each transition region can be compressed in the through thickness direction.
The first and second channels are detachably coupled such that the aft span of the first channel substantially abuts the forward span of the second channel. As a result, an axial interface is defined. Coolant leakage through the axial interface can be minimized in various ways. For example, in one embodiment, one or more seals can operatively engage the aft span of the first channel and the forward span of the second channel such that the axial interface is substantially sealed.
The first and second channels can be made of any suitable material. For example, the first channel and/or the second channel can be made of ceramic matrix composite. In one embodiment, the first and second channels can be made of different materials.
In one embodiment, the system can also include a second ring seal segment that includes a first channel and a separate second channel. Each of the first and second channels can have a radially inwardly concave surface. Further, the first and second channels can be shaped so as to form an extension that transitions into a forward span and an aft span. The forward and aft spans can be opposite each other and can extend at an angle from the extension in a radially outward direction.
The first and second channels can be detachably coupled such that the aft span of the first channel substantially abuts the forward span of the second channel. As a result, an axial interface can be defined. In one embodiment, the first and second channels can be detachably coupled by a plurality of fasteners that operatively engage the aft span of the first channel and the forward span of the second channel.
Both the first ring seal segment and the second ring seal segment can include opposite circumferential ends. One of the circumferential ends of the first ring seal segment can substantially abut one of the circumferential ends of the second ring seal segment so as to define a circumferential interface. The circumferential interface can be substantially sealed to minimize coolant leakage through the circumferential interface. To that end, one or more seals can be attached to the outer surface of the first channel of the first ring seal segment such that they extend circumferentially beyond one of the circumferential ends of the first ring seal segment and into engagement with the outer surface of the first channel of the second ring seal segment. Alternatively or in addition, one or more seals can operatively engage the circumferential ends of the first and second ring seal segments that form the circumferential interface.
Embodiments of the invention are directed to a construction for a turbine engine ring seal segment that can better distribute the operational stresses imposed thereon. Aspects of the invention will be explained in connection with one possible ring seal segment, but the detailed description is intended only as exemplary. An embodiment of the invention is shown in
The ring seal segment 40 can include a plurality of separate channels 42. In one embodiment, there can be a first channel 44 and a second channel 46. The first and second channels 44, 46 can have a generally U-shaped cross-section. Each of the channels 44, 46 can include a forward span 48 and an aft span 50. The forward span 48 and the aft span 50 of each channel 44, 46 can be connected by an axial extension 52. The terms “forward” and “aft” are intended to mean relative to the direction of the gas flow 54 through the turbine section when the ring seal segment 40 is installed in its operational position. The ring seal segment 40 can have an axial upstream end 56 and an axial downstream end 58. Each ring seal segment 40 can have an inner surface 60 and an outer surface 62. The inner surface 60 can be radially inwardly concave.
The forward span 48 and the aft span 50 can extend from the extension 52 in a generally radially outward direction. In one embodiment, the forward and aft spans 48, 50 can extend at substantially 90 degrees from the extension 52. Thus, when the ring seal segment 40 is in its operational position, the forward and aft spans 48, 50 can extend substantially radially outward relative to the axis of the turbine 64. The spans 48, 50 can extend at angles greater than or less than 90 degrees so as to form an acute or obtuse angle relative to the extension 52. The forward and aft spans 48, 50 can extend at the same angle or at different angles relative to the extension 52. There can be a transition region 49 between each of the spans 48, 50 and the axial extension 52. The transition region 49 can be configured as a fillet.
The ring seal segment 40 can have a first circumferential end 66 and a second circumferential end 68. The term “circumferential” is intended to mean relative to the turbine axis 64 when the ring seal segment 40 is installed in its operational position. The ring seal segment 40 can be curved circumferentially as it extends from the first circumferential end 66 to the second circumferential end 68.
The first and second channels 44, 46 can be made of any material suited for the high temperature and operational loads of the turbine environment. For instance, the first and second channels 44, 46 can be made of ceramic matrix composite (CMC). In one embodiment, the first and second channels 44, 46 can be made of an oxide-oxide CMC, such as AN-720, which is available from COI Ceramics, Inc., San Diego, Calif. At least one of the first and second channels 44, 46 can be made of a hybrid oxide CMC. An example of such a such a material system is disclosed in U.S. Pat. No. 6,733,907, which is incorporated herein by reference. However, the channels 44, 46 can be made of other CMC materials, including non-oxide based CMCs. Further, the channels can be made of non-CMC materials.
The first and second channels 44, 46 can be made of the same material, but, in some embodiments, the first and second channels 44, 46 can be made of different materials. Thus, material selection can be optimized based on different requirements along the ring seal segment 40. For example, a high temperature CMC may be well suited for those channels 42 that form or are proximate the axial upstream end 56 of the ring seal segment 40. Those channels 42 forming or located near the axial downstream end 58 of the ring seal segment 40, where the temperature and pressure of the combustion gases have decreased, can be made of a different CMC or a non-CMC material.
A CMC material includes a ceramic matrix and a plurality of fibers within the matrix. The fibers of the CMC can be arranged as needed to achieve the desired strength characteristics. For instance, the fibers 70 can be oriented to provide anisotropic, orthotropic, or in-plane isotropic properties. In one embodiment, a substantial portion of the fibers at least in the extension 52 of each channel 44, 46 can be substantially parallel to the turbine gas flow path 54. In one embodiment, the fibers can be arranged at substantially 90 degrees relative to each other, such as a 0-90 degree orientation or a +/−45 degree orientation. The fibers in the forward and aft spans 48, 50 can extend substantially parallel to the direction of each of those spans 48, 50. Again, these are merely examples as the fibers 70 of the CMC can be arranged as needed.
The first and the second channels 44, 46 are formed separately by any suitable process. When made of CMC, the channels 44, 46 can be formed by any suitable fabrication technique, such as winding, weaving and lay-up. The first and second channels 44, 46 can be substantially identical to each other. However, aspects of the invention also include embodiments in which at least one of the plurality of channels 42 is different from the other channels 42 in at least one respect including any of those discussed above. In one embodiment, the axial length of the extension 52 of the first channel 44 and the axial length of the extension 52 of the second channel 46 can be different. Alternatively or in addition, the thickness of the extension 52 of the first channel 44 can be different from the thickness of the extension 52 of the second channel 46.
At least a portion of the first and second channels 44, 46 can be coated with a thermal insulating material 70. For instance, the thermal insulating material 70 can be applied to the inner surface 60 of each channel 44, 46 in the extension 52 or other portions of the channels 44, 46 that would otherwise be exposed to the combustion gases 54 in the turbine. In one embodiment, the thermal insulating material 70 can be friable graded insulation (FGI). Various examples of FGI are disclosed in U.S. Pat. Nos. 6,676,783; 6,670,046; 6,641,907; 6,287,511; 6,235,370; and 6,013,592, which are incorporated herein by reference. The thermal insulating material 70 can be attached to each channel 44, 46 individually.
The first and second channels 44, 46 can be arranged in an axially abutted manner so as to collectively form the ring seal segment 40. For example, the aft span 50 of the first channel 44 can substantially abut the forward span 48 of the second channel 46 to thereby form an axial interface 72. The term “substantially abut” and variants thereof is intended to mean that at least a portion of the forward and aft spans 48, 50 forming the interface directly contact each other, or they can be slightly spaced.
The circumferential ends 66, 68 of the first channel 44 can be substantially flush with the circumferential ends 66, 68 of the second channel 46, as shown in
The abutting channels 44, 46 can be detachably coupled to each other in any of a number of ways. For example, the first and second channels 44, 46 can be detachably coupled by one or more elongated fasteners, such as a pin 74 as shown in
The ring seal segment 40 can be operatively connected to one or more stationary support structures in the turbine section of the engine including, for example, the engine casing, a vane carrier 75 or one or more isolation rings. The ring seal segment 40 can be directly or indirectly connected to any of these stationary support structures.
The channels 42 can be attached to the adapter 76 by, for example, pins 74 or other elongated fasteners. To that end, the forward and aft spans 48, 50 of each channel 42 can include cutouts 84. The cutouts 84 can be substantially aligned so that an elongated fastener can be passed therethrough and into engagement with the adapter 76. The fasteners can engage the adapter 76 in various ways including, for example, threaded engagement. To accommodate differential thermal growth of the fasteners and the channels 42, the cutouts 84 can be slotted or oversized. Any suitable quantity of fasteners can be used to connect the forward and aft spans 48, 50 of each channel 42 to the adapter 76. In one embodiment, the forward and aft spans 48, 50 of each channel 42 can be operatively connected to the adapter 76 by three pins 74. The pins 74 can be arranged in any suitable manner.
Additional ring seal segments 40 can be attached to the stationary support structure in a similar manner to that described above. The plurality of the ring seal segments 40 can be installed so that each of the circumferential ends 66, 68 of one ring seal segment 40 substantially abuts one of the circumferential ends 66, 68 of a neighboring ring seal segment 40 so as to collectively form an annular ring seal. The substantially abutting circumferential ends 66, 68 of the ring seal segments 40 can form a circumferential interface 86 (see
During engine operation, a coolant, such as air, can be supplied to the outer surface 62 of the ring seal segments 40. The coolant can be delivered through one or more passages (not shown) in the adapter 76. The coolant can be supplied at a high pressure to prevent the hot combustion gases 54 from infiltrating past the ring seal segments 40. The components beyond the ring seal segments 40 are typically not designed to withstand the high temperatures of the combustion gases 54. However, there is a potential for coolant to leak into the turbine gas path 54 through the axial interface 72 between abutting channels 42 and/or the circumferential interface 86 between abutting ring seal segments 40. Such coolant leakage can adversely impact engine performance. To minimize the escape of coolant through the axial and circumferential interfaces 72, 86, there can be various sealing systems operatively associated with the ring seal segment 40.
With respect to the axial interface 72, one or more seals can operatively engage portions of the forward and aft spans 48, 50 of two adjacent channels 42 that form the interface 72.
Alternatively or in addition, one or more seals 91 and/or bonding material 95 can be applied between the outer surfaces 62 of the channels 42 that form the interface 72, such as between the aft span 50 of one channel 42 and the forward span 48 of a axially downstream channel 42, as shown in
Likewise, leakage through the circumferential interface 86 can be minimized in various ways. In one embodiment, one or more seals 92 can operatively engage portions of each of the circumferentially abutting channels 42 forming the circumferential interface 86.
A portion of the seal 92 can extend beyond one or both of the circumferential ends 66, 68 of each channel 42. The extending portion can be received in the neighboring channel 42 of an adjacent ring seal segment 40. The seal 92 can be any suitable seal. In one embodiment, the seal 92 can be made of sheet metal. In another embodiment, the seal 92 can be made of CMC. The seal 92 can be held in place in any suitable manner. For instance, the seal 92 can include cutouts 94. In such case, the pin 74 connecting the channels 42 can also hold the seal 92 in place. The seal 92 can be pinned to one or both of the neighboring channels 42 forming the circumferential interface 86. The seal 92 can be bonded to one or both of the channels 42 forming the interface 86.
Alternatively or in addition, one or more seals 93 and/or bonding material 97 can be applied between the inner surfaces 60 of the channels 42 that form the circumferential interface 86, such as between the first circumferential end 66 of one channel 42 and the second circumferential end 68 of a circumferentially adjacent channel 42, as shown in
Further, as discussed above, the circumferential interfaces of the first channels can be staggered or otherwise offset from the circumferential interfaces of the second channels. As a result, a tortuous path for any potential leakage flow is created.
The ring seal segment according to aspects of the invention can manage the loads that it is subjected to during engine operation. In prior ring seal segment designs, an area of high stress occurs at corner regions. The stress is directly related to bending load at these corner regions. The load is mainly imposed by the pressure of the coolant supplied to the backside of the ring seal segment. The ring seal segment according to aspects of the invention is well suited to reduce the load by increasing the number of reaction points. That is, by breaking the ring seal segment into a plurality of U-shaped channels, as described above, each channel can carry a portion of the bending load proportional to its axial length. Thus, the greater the number of separate channels forming the ring seal segment, the lower the bending stress in each channel, resulting in lower interlaminar stresses (for CMC channels) and increased structural integrity. Because the multi-channel ring seal design according to aspects of the invention can distribute the stresses imposed on the ring seal segment, the thickness of the individual channels can be reduced. The reduced thickness of the channels can lead to material cost savings and can reduce thermal gradients across each channel.
The ring seal segment 40 according to aspects of the invention can be configured to minimize interlaminar tensile stresses that can develop along the transition regions 49 of each channel 42. To that end, the channels 42 can be preloaded; that is, at least a portion of the transition region 49 can be placed in interlaminar compression in the through thickness direction, which can extend from one of the inner surface 60 and the outer surface 62 to the opposite one of the inner and outer surfaces 60, 62. Generally, such preload can be achieved by forcing the forward and aft spans 48, 50 of the channels 42 toward each other. Such preloading can greatly increase the load carrying capability of the ring seal segment 40.
In an alternative embodiment, shown in
Wedges 112 can be provided. The wedges can have any suitable shape and can be made of any suitable material. The wedges 112 can be driven between the spans 48, 50 forming the axial interface 72. As a result, the spans 48, 50 forming the interface 72 can be forced toward the opposite span of the channel 42. The wedges 112 can be held in place in any suitable manner.
The above preloading arrangements can place a compressive load on the transition regions 49 of each channel 42 in the through thickness direction. Such a compressive load is particularly beneficial when the channels 42 are made of CMC because CMCs are especially strong in compression in the through thickness direction. As a result, stress on the transition region 49 can be reduced, allowing the ring seal segment to carry the backside coolant loads, as discussed previously.
Because the ring seal segment 40 is formed by a plurality of individual channels 42, the ring seal can expand the possible cooling schemes for the ring seal segments 40. As is known, the pressure of the combustion gases 54 decreases as the gases 54 travel through the turbine section. According to aspects of the invention, the coolant supplied to the individual channels 42 of the ring seal segment 40 can be controlled to account for such a decrease in pressure. For instance, referring to
The configuration of a ring seal segment 40 in accordance with aspects of the invention can further aid in minimizing the leakage of hot combustion gases 54 in the clearance 100 between the ring seal segment 40 and the neighboring row of turbine blades 102. Such leakage flow can decrease engine efficiency. To minimize such leakage, the thermal insulating coating 70 can be staggered along the gas path 54 so as to create a more tortuous path for gases 50 to flow between the ring seal segment 40 and the nearby blades 102.
The foregoing description is provided in the context of one possible ring seal segment for use in a turbine engine. Aspects of the invention are not limited to the examples presented herein. While the above discussion concerns a ring seal segment, the construction described herein has equal application to a full 360 degree ring seal body. Further, the following description concerned a ring seal segment made of two separate channels. However, it will be understood that the ring seal segment can be made of more than two channels. Thus, it will of course be understood that the invention is not limited to the specific details described herein, which are given by way of example only, and that various modifications and alterations are possible within the scope of the invention as defined in the following claims.
