U.S. patent application number 13/709578 was filed with the patent office on 2014-06-12 for turbo-machine component and method.
This patent application is currently assigned to GENERAL ELECTRIC COMPANY. The applicant listed for this patent is General Electric Company. Invention is credited to Lisa AMMANN, Brian Peter ARNESS, Robert MEYER.
Application Number | 20140161585 13/709578 |
Document ID | / |
Family ID | 50881128 |
Filed Date | 2014-06-12 |
United States Patent
Application |
20140161585 |
Kind Code |
A1 |
ARNESS; Brian Peter ; et
al. |
June 12, 2014 |
TURBO-MACHINE COMPONENT AND METHOD
Abstract
A component, a component manufacturing process, and a component
operation process are disclosed. The component has a diffuser
permitting compressible fluid to flow throughout a first region and
a second region of the diffuser at a decreasing velocity. The
diffuser includes a coating collection feature. The component
manufacturing process includes positioning the component and
applying the coating to at least a surface of the component outside
of the diffuser and to at least a portion of the second region, not
to the first region, to the coating collection feature, or a
combination thereof. The component operation process includes
positioning the component and transporting the compressible fluid
through the diffuser.
Inventors: |
ARNESS; Brian Peter;
(Simpsonville, SC) ; MEYER; Robert; (Simpsonville,
SC) ; AMMANN; Lisa; (Simpsonville, SC) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
General Electric Company; |
|
|
US |
|
|
Assignee: |
GENERAL ELECTRIC COMPANY
Schenectady
NY
|
Family ID: |
50881128 |
Appl. No.: |
13/709578 |
Filed: |
December 10, 2012 |
Current U.S.
Class: |
415/1 ; 29/428;
415/177; 415/208.1 |
Current CPC
Class: |
F01D 5/288 20130101;
F05D 2230/90 20130101; Y10T 29/49826 20150115; F05D 2240/304
20130101; F01D 5/186 20130101 |
Class at
Publication: |
415/1 ;
415/208.1; 415/177; 29/428 |
International
Class: |
F01D 9/02 20060101
F01D009/02 |
Goverment Interests
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
[0001] The United States Government retains license rights in this
invention and the right in limited circumstances to require the
patent owner to license others on reasonable terms by the terms of
Government Contract No. 9FB-05 awarded by the United Stated
Department of Energy.
Claims
1. A component having a diffuser, the diffuser comprising: a first
region having a first section with a first cross-sectional area; a
second region having a second section with a second cross-sectional
area that is greater than the first cross-sectional area; a coating
collection feature at least partially positioned within the second
region; and a flow-path arranged and disposed to permit
compressible fluid to flow throughout the first region and the
second region of the diffuser at a decreasing velocity.
2. The component of claim 1, further comprising a coating at least
partially within the second region.
3. The component of claim 2, wherein the coating is a
thermal-barrier coating.
4. The component of claim 2, wherein the coating abuts the
flow-path.
5. The component of claim 2, wherein an uncoated portion of the
second region abuts the flow-path.
6. The component of claim 2, wherein the coating is at least
partially positioned on a surface of the component outside the
diffuser.
7. The component of claim 6, wherein the portion of the coating on
the surface includes a thickness of at least 5 mils.
8. The component of claim 6, wherein the portion of the coating on
the surface includes a thickness of at least 20 mils.
9. The component of claim 6, wherein the portion of the coating on
the surface includes a thickness of at least 30 mils.
10. The component of claim 1, further comprising a third region
having a third section with a third cross-sectional area that is
greater than the first cross-sectional area and less than the
second cross-sectional area, the third section abutting the
flow-path.
11. The component of claim 1, further comprising a coating in
contact with the coating collection feature.
12. The component of claim 1, wherein the component is a turbine
component.
13. The component of claim 12, wherein the component is a blade and
the diffuser is arranged and disposed for air flow.
14. The component of claim 13, wherein the diffuser is positioned
on or proximal to a trailing edge of the blade.
15. The component of claim 13, wherein the diffuser is positioned
on or proximal to a pressure side of the blade.
16. The component of claim 1, wherein the flow-path in the diffuser
is arranged and disposed to permit the compressible fluid to
decrease velocity at a substantially constant rate.
17. The component of claim 1, wherein the flow-path in the diffuser
is arranged and disposed to permit the compressible fluid to
decrease velocity at an increasing rate.
18. The component of claim 1, wherein the flow-path is arranged and
disposed to permit the compressible fluid to flow throughout the
diffuser at the decreasing velocity.
19. A component manufacturing process, comprising: positioning the
component, the component having a diffuser, the diffuser
comprising: a first region having a first section with a first
cross-sectional area; a second region having a second section with
a second cross-sectional area that is greater than the first
cross-sectional area; a coating collection feature at least
partially positioned within the second region; and a flow-path
arranged and disposed to permit compressible fluid to flow
throughout the first region and the second region of the diffuser
at a decreasing velocity. applying a coating to at least a surface
of the component outside of the diffuser and to at least a portion
of the second region, not to the first region, to the coating
collection feature, or a combination thereof.
20. A component operation process, the process comprising:
positioning the component having a diffuser, the diffuser
comprising: a first region having a first section with a first
cross-sectional area; a second region having a second section with
a second cross-sectional area that is greater than the first
cross-sectional area; a coating collection feature at least
partially positioned within the second region; and a flow-path
arranged and disposed to permit a compressible fluid to flow
throughout the first region and the second region of the diffuser
at a decreasing velocity; and transporting the compressible fluid
through the diffuser.
Description
FIELD OF THE INVENTION
[0002] The present invention is directed to components, processes
of manufacturing components, and processes of operating components.
More specifically, the present invention relates to components and
processes involving diffusers.
BACKGROUND OF THE INVENTION
[0003] Diffusers permit airflow to and from systems relying upon
air flow. For example, diffusers cool components or portions of
components subjected to high temperature due to operation of the
component, the environment of the component, or combinations
thereof. For example, diffusers in turbine blades cool the blades,
which operate under extreme temperatures during power generation
and/or thrust generation. Diffusers in nozzles cool portions of
nozzles proximal to flame regions and/or provide air to the flame
region, thereby assisting with combustion.
[0004] These diffusers and other known diffusers facilitate
expansion of compressible fluids and/or provide cooling in other
systems by reducing airflow velocity by having a cross-sectional
area at a diffuser exit that is larger than a cross-sectional area
at a diffuser entrance. As the cross-sectional area increases, the
velocity of the flow decreases, thereby lowering pressure of the
flow. At the exit, the diffuser can be open to another component,
such as a compressor, a flame region, a pressure side of a blade,
or any other suitable component or environment.
[0005] Generally, the cross-sectional areas of diffusers increase
at constant rates. Such constant rate increases permit the velocity
to decrease at a constant rate or an increasing rate. For example,
known diffusers generally have a geometry that is either partially
conical, curvilinear, stepped, and/or partially tubular. Such
geometries facilitate a decrease in velocity.
[0006] Clogging of diffusers can modify the internal profile of the
diffuser, thereby modifying the velocity profile of the diffuser.
Prior attempts to use coatings on surfaces outside of diffusers but
still proximal to the diffusers have resulted in such clogging or
otherwise modifying of the internal profiles of the diffusers. For
example, such attempts resulted in constrictions of flow-paths
within diffusers, thereby undesirably increasing velocity through
certain portions within the diffuser. Such modifications to the
rate of fluid flow within the diffusers could result in operational
inefficiencies, inadequate fluid transport, or failure of a
part.
[0007] A component, a component manufacturing process, and a
component operation process that do not suffer from one or more of
the above drawbacks would be desirable in the art.
BRIEF DESCRIPTION OF THE INVENTION
[0008] In an exemplary embodiment, a component has a diffuser that
includes a first region having a first section with a first
cross-sectional area, a second region having a second section with
a second cross-sectional area that is greater than the first
cross-sectional area, a coating collection feature at least
partially positioned within the second region, and a flow-path
arranged and disposed to permit compressible fluid to flow
throughout the first region and the second region of the diffuser
at a decreasing velocity.
[0009] In another exemplary embodiment, a component-manufacturing
process includes positioning the component and applying a coating
to at least a surface of the component outside of the diffuser and
to at least a portion of the second region, not to the first
region, to the coating collection feature, or a combination
thereof. The component has a diffuser including a first region
having a first section with a first cross-sectional area, a second
region having a second section with a second cross-sectional area
that is greater than the first cross-sectional area, a coating
collection feature at least partially positioned within the second
region, and a flow-path arranged and disposed to permit
compressible fluid to flow throughout the first region and the
second region of the diffuser at a decreasing velocity.
[0010] In another exemplary embodiment, a component operation
process includes positioning the component and transporting a
compressible fluid through a diffuser. The component has a diffuser
including a first region having a first section with a first
cross-sectional area, a second region having a second section with
a second cross-sectional area that is greater than the first
cross-sectional area, a coating collection feature at least
partially positioned within the second region, and a flow-path
arranged and disposed to permit compressible fluid to flow
throughout the first region and the second region of the diffuser
at a decreasing velocity.
[0011] Other features and advantages of the present invention will
be apparent from the following more detailed description of the
preferred embodiment, taken in conjunction with the accompanying
drawings which illustrate, by way of example, the principles of the
invention.
BRIEF DESCRIPTION OF THE DRAWINGS
[0012] FIG. 1 shows a schematic sectional view of an exemplary
component without a coating according to the disclosure.
[0013] FIG. 2 shows a schematic sectional view of an exemplary
component with a coating according to the disclosure.
[0014] FIG. 3 shows a schematic sectional view of an exemplary
coated component with a linear coating collection feature according
to the disclosure.
[0015] FIG. 4 shows a schematic sectional view of an exemplary
coated component with a curved coating collection feature according
to the disclosure.
[0016] FIG. 5 shows a schematic sectional view of an exemplary
coated component according to the disclosure.
[0017] FIG. 6 shows a schematic sectional view of an exemplary
coated component according to the disclosure.
[0018] FIG. 7 shows a schematic sectional view of an exemplary
component with a coating applied at an angled orientation according
to an exemplary process of the disclosure.
[0019] FIG. 8 shows a schematic sectional view of an exemplary
component having coating on a surface exterior to a diffuser but
not on the diffuser according to the disclosure.
[0020] FIG. 9 shows a schematic view of an exemplary component
being a turbine blade according to the disclosure.
[0021] FIG. 10 shows a schematic view of an exemplary component
being a nozzle according to the disclosure.
[0022] Wherever possible, the same reference numbers will be used
throughout the drawings to represent the same parts.
DETAILED DESCRIPTION OF THE INVENTION
[0023] Provided is an exemplary component, a component
manufacturing process, and a component operation process.
Embodiments of the present disclosure permit airflow for cooling
components, reduce or eliminate partial or complete blockages of
diffusers, permit operation in more harsh environments (for
example, environments having greater thermal gradients), permit
additional control of fluid flow-paths and/or fluid velocity
profiles within diffusers, facilitate a controlled decrease in
velocity of compressible fluids within diffusers, increase
operational efficiencies, or combinations thereof.
[0024] FIG. 1 shows a portion of a component 100 according to an
embodiment of the disclosure. The component 100 is any suitable
article for transport of a fluid. For example, in one embodiment,
the component 100 is a turbine component, such as, a turbine blade
902 (see FIG. 9), a nozzle 910 (see FIG. 10), or any other article
containing one or more diffusers 102 for transporting a fluid, such
as a compressible fluid, along a predetermined flow-path 114.
[0025] Generally, the diffuser 102 is any suitable geometry. In one
embodiment, portions of the diffuser 102 include a cylindrical
geometry, a tapered geometry, a partially conical geometry, a
curvilinear geometry, a complex geometry, or any other geometry
with an expanding cross-sectional area through a portion of the
diffuser 102 or throughout the diffuser 102. The size, position,
and shape of the diffuser 102 corresponds to the component 100
including the diffuser 102, the amount of the diffusers 102
included in the component 100, the proximity between the diffusers
102 used in the component 100, the amount of cooling and/or other
fluid transport to be performed by the diffusers 102, manufacturing
technologies employed in forming the diffusers 102, or combinations
thereof.
[0026] The diffuser 102 includes any suitable number of regions,
for example, two regions, three regions, four regions, five
regions, six regions, or more. In one embodiment, the diffuser 102
has a first region 104 and a second region 106. The first region
104 has a first section 111 with a first cross-sectional area.
Overall, the first region 104 includes constant cross-sectional
areas or increasing cross-sectional areas. The second region 106
has a second section 113 with a second cross-sectional area.
Overall, the second region 106 includes constant cross-sectional
areas or increasing cross-sectional areas. The second
cross-sectional area in the second section 113 is greater than the
first cross-sectional area in the first section 111, thereby
permitting a decrease in velocity of the compressible fluid from
between the first section 111 and the second section 113, between
the first region 104 and the second region 106, otherwise along the
flow-path 114, or combinations thereof.
[0027] In one embodiment, the diffuser 102 further includes a third
region 108 between the first region 104 and the second region 106.
In this embodiment, the third region 108 is oriented at a
predetermined angle 109 in comparison to the first region 104, for
example, between about 1 degree and about 5 degrees, between about
1 degree and about 10 degrees, between about 5 degrees and about 10
degrees, between about 10 degrees and about 20 degrees, about 1
degree, about 5 degrees, about 10 degrees, about 15 degrees, about
20 degrees, or any suitable combination or sub-combination
thereof.
[0028] The flow-path 114 of the diffuser 102 extends through the
first region 104, the second region 106, and any other regions of
the diffuser 102, for example, the third region 108. The flow-path
114 abuts all or a portion of one or more of the first region 104,
the second region 106, the third region 108, the coating collection
feature 112, and a portion or all surfaces of a coating 202 (see
FIG. 2) in the diffuser 102.
[0029] The diffuser 102 includes the coating collection feature
112. The coating collection feature 112 prevents the coating 202
from travelling into undesired portions of the diffuser 102 (such
as the first region 104) and/or maintains the coating 202 in
desired portions (such as the second region 106). For example, in
one embodiment, the coating collection feature 112 prevents a
portion or all of the coating 202 from travelling into the first
region 104 and/or the third region 108 of the diffuser 102 during
application of the coating 202. In another embodiment, in addition
to regions outside of the diffuser 102, a portion or all of the
coating 202 is maintained in the second region 106 of the diffuser
102 by the coating collection feature 112.
[0030] In one embodiment, the coating collection feature 112 is at
least partially positioned within the second region 106, between
the second region 106 and the first region 102, between the second
region 106 and the third region 108, or a combination thereof. The
coating collection feature 112 includes a geometry controlling the
travelling of the coating 202. In one embodiment, as shown in FIGS.
1-2, the geometry is an angled recess 116. The angled recess 116
widens the diffuser 102 along the flow-path 114, thereby decreasing
velocity of the compressible fluid traveling along the flow-path
114.
[0031] The diffuser 102 controls the velocity of the compressible
fluid flowing through the diffuser 102, an amount of cooling of the
component 100 facilitated by the diffuser 102, an amount of the
compressible fluid transported, or combinations thereof. In one
embodiment, the flow-path 114 of the diffuser 102 is arranged and
disposed to permit the compressible fluid to flow throughout the
first region 104 and the second region 106 of the diffuser 102 at a
decreasing velocity. In a further embodiment, the flow-path 114 is
arranged and disposed to permit the compressible fluid to flow
throughout the diffuser 102 at the decreasing velocity. In one
embodiment, the flow-path 114 is arranged and disposed to permit
the compressible fluid to decrease velocity at a predetermined
rate, for example, a substantially constant rate or an increasing
rate.
[0032] Referring to FIG. 2, in one embodiment, the diffuser 102
includes a coating 202, such as a thermal barrier coating, for
example, a coating having yttria-stabilized zirconia, ytterbium
zirconium, fully-stabilized gadolinia zirconia, alumina,
pyrochlores, or combinations thereof. In a further embodiment, the
coating 202 further includes a bonding layer, for example, a MCrAlY
alloy (where M identifies one or more of Fe, Ni, and Co),
intermetallic aluminide, or any other suitable material. The
coating 202 is applied to the diffuser 102 by any suitable process,
for example, physical vapor deposition, chemical vapor deposition,
cold spray, or a combination thereof.
[0033] The coating collection feature 112 is positioned and
oriented to prevent the coating 202 and/or other debris from
disrupting the flow-path 114 and/or a predetermined velocity
profile of the diffuser 102. FIGS. 1-5 show embodiments with a
portion or all of the coating collection feature 112 positioned
substantially directly below an upper surface 118 of the component
100. FIGS. 6-8 show embodiments with a portion or all of the
coating collection feature 112 not covered by the upper surface
118.
[0034] FIG. 3 shows an embodiment with the coating collection
feature 112 completely covered by the upper surface 118. In this
embodiment, the coating 202 is substantially or entirely prevented
from flowing into the first region 104, but the coating 202 is
inconsistent in thickness within the second region 106, which may
impact the flow-path 114, for example, by causing the decrease in
velocity of the compressible fluid to be slowed or partially
reversed.
[0035] FIG. 4 shows an embodiment with the coating collection
feature 112 completely covered by the upper surface 118. In this
embodiment, the coating collection feature 112 tapers or curves
from the first region 104, thereby substantially or entirely
preventing the coating 202 from flowing into the first region 104.
In this embodiment, the thickness of the coating 202 in the second
region is more consistent than the embodiment shown in FIG. 3, but
a coating thickness 208 that can be applied without the coating 202
entering the first region 104 is lower than the coating thickness
of the embodiment of FIG. 3.
[0036] FIG. 5 shows an embodiment with the coating collection
feature 112 defining a large bored out portion 502 forming the
second region 106. In the embodiment shown in FIG. 5, the coating
collection feature 112 is completely covered by the upper surface
118. In this embodiment, the coating 202 fills the second region
106 and the flow-path 114 substantially decreases velocity of the
compressible fluid. In a further embodiment, the coating 202 is
applied at a greater thickness, thereby modifying the amount of the
decrease in the velocity of the compressible fluid along the
flow-path 114. The embodiment shown in FIG. 6 shows the coating
collection feature 112 with a similar geometry but not covered by
the upper surface 118. The coating 202 in the second region 106
slightly decreases the velocity of the compressible fluid along the
flow-path 114.
[0037] FIG. 7 shows an embodiment with the coating collection
feature 112 completely uncovered relative to the upper surface 118.
FIG. 8 shows an embodiment with the coating collection feature 112
being aligned with the edge of the upper surface 118. In one
embodiment, the portions of the component 100 and/or the diffuser
that are coated are based upon the application technique employed.
For example, referring to FIG. 7, in one embodiment, the coating
202 is applied at an angled orientation 702. The angled orientation
702 substantially or entirely prevents the coating 202 from being
applied to the first region 104. In one embodiment, the angled
orientation 702 is parallel with and/or in line with a portion or
all of the angled recess 116. Additionally or alternatively,
referring to FIG. 8, in one embodiment, the coating 202 is
selectively applied to predetermined portions of the component 100,
such as the surface 206. In this embodiment, only portions of the
second region 106 include the coating 202 and the coating 202
thickness is inconsistent.
[0038] The orientation of the coating collection feature 112 is
based upon the geometry of the coating collection feature 112. For
example, in one embodiment, as shown in FIGS. 1-2, the coating
collection feature 112 includes a linear geometry. In one
embodiment, the coating collection feature 112 is oriented at a
predetermined coating collection feature angle 115 in comparison to
the first region 104 or the second region 106, for example, between
about 10 degrees and about 150 degrees, between about 10 degrees
and about 90 degrees, between about 10 degrees and about 45
degrees, between about 10 degrees and about 30 degrees, between
about 30 degrees and about 90 degrees, between about 30 degrees and
about 60 degrees, between about 30 degrees and about 45 degrees,
between about 45 degrees and about 60 degrees, between about 45
degrees and about 90 degrees between about 60 degrees and about 90
degrees, between about 60 degrees and about 150 degrees, between
about 90 degrees and about 150 degrees, about 90 degrees (as shown
in FIGS. 1-2, 7, and 8), about 120 degrees (as shown in FIGS. 3, 5,
and 6), about 60 degrees, about 30 degrees, about 10 degrees, or
any suitable combination or sub-combination thereof.
[0039] In one embodiment, the coating 202 is applied in a
predetermined portion of the diffuser 102. For example, in one
embodiment, the coating 202 is at least partially or fully within
the second region 106, at least partially or fully in contact with
the coating collection feature 112, or a combination thereof. In
one embodiment, the coating 202 abuts the flow-path 114 and/or an
uncoated portion 204 of the second region 106 abuts the flow-path
114. In a further embodiment, the coating 202 is at least partially
positioned on a surface 206 of the component 100 outside the
diffuser 102.
[0040] The coating 202 is applied at a predetermined thickness,
such as the thickness 208. Suitable thickness include, but are not
limited to, at least about 5 mils, at least about 10 mils, at least
about 20 mils, at least about 30 mils, between about 5 mils and
about 30 mils, between about 10 mils and about 30 mils, between
about 20 mils and about 30 mils, between about 10 mils and about 20
mils, between about 5 mils, or any suitable combination or
sub-combination thereof.
[0041] In one embodiment, the coating 202 is applied by positioning
the component 100 and applying the coating 202 to at least a
surface, such as the surface 206 outside of the diffuser 102 of the
component 100. In this embodiment, the coating 202 is also applied
to at least a portion of the second region 106, does not contact
the first region 104, contacts the coating collection feature 112,
or a combination thereof. The portions of the diffuser 102 that are
coated or remain uncoated correspond to the application technique,
the thickness of the coating 202 applied, the geometry of the
coating collection feature 112, the configuration of the second
region 106, or combinations thereof.
[0042] In one embodiment, the compressible fluid is transported
along the flow-path 114 through the diffuser 102. For example,
referring to FIG. 9, in one embodiment, the compressible fluid is
air and the component 100 is a turbine blade 902. The diffusers 102
are positioned along any portion of the turbine blade 902, for
example, on or proximal to a pressure side 904, on or proximal to a
leading edge 906, on or proximal to a trailing edge 908, on or
proximal to any other portion of the turbine blade 902 that
benefits from cooling, or a combination thereof. In this
embodiment, the properties of the coating 202 permit operation of
the turbine blade 902 with a greater temperature gradient and/or
greater fatigue resistance.
[0043] Referring to FIG. 10, in one embodiment, the compressible
fluid is air and the component 100 is a nozzle 910. The diffusers
102 are positioned in any portion of the nozzle 910, for example,
around a flame region 912 or any region that benefits from cooling.
In this embodiment, the properties of the coating 202 permit
operation of the nozzle 910 with a greater temperature gradient
and/or greater fatigue resistance.
[0044] While the invention has been described with reference to a
preferred embodiment, it will be understood by those skilled in the
art that various changes may be made and equivalents may be
substituted for elements thereof without departing from the scope
of the invention. In addition, many modifications may be made to
adapt a particular situation or material to the teachings of the
invention without departing from the essential scope thereof.
Therefore, it is intended that the invention not be limited to the
particular embodiment disclosed as the best mode contemplated for
carrying out this invention, but that the invention will include
all embodiments falling within the scope of the appended
claims.
* * * * *