U.S. patent application number 14/014528 was filed with the patent office on 2015-03-05 for gas turbine components with porous cooling features.
This patent application is currently assigned to General Electric Company. The applicant listed for this patent is General Electric Company. Invention is credited to Brian Brzek, Srikanth Chandrudu Kottilingam, Benjamin Paul Lacy, David Edward Schick.
Application Number | 20150064019 14/014528 |
Document ID | / |
Family ID | 52470581 |
Filed Date | 2015-03-05 |
United States Patent
Application |
20150064019 |
Kind Code |
A1 |
Lacy; Benjamin Paul ; et
al. |
March 5, 2015 |
Gas Turbine Components with Porous Cooling Features
Abstract
The present application provides a hot gas path component for
use with a gas turbine engine. The hot gas path component may
include an airfoil, an internal cooling cavity, and a porous
section created by a direct metal laser melting technique. The
porous section may be built into the airfoil or the airfoil may be
built separately and attached to the airfoil.
Inventors: |
Lacy; Benjamin Paul; (Greer,
SC) ; Kottilingam; Srikanth Chandrudu; (Simpsonville,
SC) ; Brzek; Brian; (Niskayuna, NY) ; Schick;
David Edward; (Greenville, SC) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
General Electric Company |
Schenectady |
NY |
US |
|
|
Assignee: |
General Electric Company
Schenectady
NY
|
Family ID: |
52470581 |
Appl. No.: |
14/014528 |
Filed: |
August 30, 2013 |
Current U.S.
Class: |
416/97A |
Current CPC
Class: |
B22F 3/1055 20130101;
F01D 5/183 20130101; Y02P 10/295 20151101; F01D 5/186 20130101;
F05D 2300/514 20130101; F01D 5/187 20130101; B22F 5/04 20130101;
B22F 5/10 20130101; F05D 2300/612 20130101; B22F 7/004 20130101;
Y02P 10/25 20151101 |
Class at
Publication: |
416/97.A |
International
Class: |
F01D 5/18 20060101
F01D005/18 |
Goverment Interests
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
[0001] This invention was made with U.S. government support under
contract number DE-FC26-05NT42643 awarded by the Department of
Energy. The government has certain rights in this invention.
Claims
1. A hot gas path component for use with a gas turbine engine,
comprising: an airfoil; an internal cooling cavity; and a porous
section created by a direct metal laser melting technique.
2. The hot gas path component of claim 1, wherein the porous
section is built into the airfoil.
3. The hot gas path component of claim 1, wherein the porous
section is built separately and attached to the airfoil.
4. The hot gas path component of claim 1, wherein the airfoil
comprises a pressure side and a suction side and wherein the porous
section is within the suction side.
5. The hot gas path component of claim 1, further comprising an
impingement sleeve adjacent to the porous section.
6. The hot gas path component of claim 1, further comprising a
plurality of film cooling holes adjacent to the porous section.
7. The hot gas path component of claim 1, wherein the porous
section comprises a porous media therein.
8. The hot gas path component of claim 7, wherein the porous media
comprises a metal foam, a ceramic foam, and/or a carbon fiber
foam.
9. The hot gas path component of claim 1, wherein the porous
section comprises a porous trailing edge section with an external
sleeve thereon in whole or in part.
10. The hot gas path component of claim 1, wherein the porous
section comprises one or more porous side sections.
11. The hot gas path component of claim 1, wherein the porous
section comprises a porous external section.
12. The hot gas path component of claim 11, wherein the porous
external section comprises an external sleeve with a plurality of
external film cooling holes.
13. The hot gas path component of claim 1, wherein the porous
section comprises a porous internal section.
14. A method of cooling a hot gas path component for use with a gas
turbine engine, comprising: providing the hot gas path component
with an internal cooling cavity; creating a porous section via a
direct metal laser melting technique; flowing a cooling medium to
the internal cooling cavity; and flowing the cooling medium through
the porous section to provide transpiration cooling.
15. The method of claim 14, wherein the creating step comprises
building up the porous section on the hot gas path component or
building the porous section separately and attaching the porous
section to the hot gas path component.
16. An airfoil for use with a gas turbine engine, comprising: a
pressure side; a suction side; an internal cooling cavity; and a
porous section created by a direct metal laser melting
technique.
17. The airfoil of claim 16, wherein the porous section is built
into the airfoil or the porous section is built separately and
attached to the airfoil.
18. The airfoil of claim 16, wherein the porous section comprises a
porous trailing edge section.
19. The airfoil of claim 16, wherein the porous section comprises
one or more porous side sections.
20. The airfoil of claim 16, wherein the porous section comprises a
porous external section and/or a porous internal section.
Description
TECHNICAL FIELD
[0002] The present application and the resultant patent relate
generally to gas turbine engines and more specifically relate to
gas turbine components with porous cooling sections created by
direct metal laser melting manufacturing techniques and the
like.
BACKGROUND OF THE INVENTION
[0003] Gas turbine systems are widely utilized in fields such as
power generation. Overall gas turbine performance and efficiency
generally may be increased by increasing internal combustion
temperatures. The components that are subject to the high
temperatures in the hot gas path, however, must be cooled. For
example, an airfoil and other components of a nozzle and the like
may be disposed in the hot gas path and exposed to the relatively
high combustion temperatures. A cooling flow therefore may be
routed from the compressor or elsewhere and provided to the various
components in the hot gas path.
[0004] A variety of methods may be used for cooling the airfoils
and the other components. These methods may include running a
cooling flow on the interior side of the component, running the
cooling flow through an impingement sleeve that impinges the flow
on the backside of the component so as to increase the heat
transfer coefficient therein, running the coolant through cooling
holes to the exterior of the component to convectively cool, and
exhausting the coolant from the cooling holes as film to provide a
layer of cool air over the exterior so as to reduce exterior
temperatures. Although the use these methods may provide adequate
cooling for the airfoils, a further increase in cooling efficiency
is desired. Such an increase in efficiency would allow a reduction
in the cooling flows required to cool the airfoils and other
components and also may provide a reduction in emissions and/or an
increase in firing temperatures.
SUMMARY OF THE INVENTION
[0005] The present application and the resultant patent thus
provide a hot gas path component for use with a gas turbine engine.
The hot gas path component may include an airfoil, an internal
cooling cavity, and a porous section created by a direct metal
laser melting technique. The porous section may be built into the
airfoil or the airfoil may be built separately and attached to the
airfoil.
[0006] The present application and the resultant patent further
provide a method of cooling a hot gas path component for use with a
gas turbine engine. The method may include the steps of providing
the hot gas path component with an internal cooling cavity,
creating a porous section via a direct metal laser melting
technique, flowing a cooling medium to the internal cooling cavity,
and flowing the cooling medium through the porous section to
provide transpiration cooling. The creating step may include
building up the porous section on the hot gas path component or
building the porous section separately and attaching the porous
section to the hot gas path component.
[0007] The present application and the resultant patent further
provide an airfoil for use with a gas turbine engine. The airfoil
may include a pressure side, a suction side, an internal cooling
cavity, and a porous section with a porous media created by a
direct metal laser melting technique.
[0008] These and other features and improvements of the present
application and the resultant patent will become apparent to one of
ordinary skill in the art upon review of the following detailed
description when taken in conjunction with the several drawings and
the appended claims.
BRIEF DESCRIPTION OF THE DRAWINGS
[0009] FIG. 1 is a schematic diagram of a gas turbine engine
showing a compressor, a combustor, and a turbine.
[0010] FIG. 2 is a sectional view of a portion of an airfoil.
[0011] FIG. 3 is a sectional view of a portion of an airfoil as may
be described herein.
[0012] FIG. 4 is an expanded view of a portion of the airfoil of
FIG. 3.
[0013] FIG. 5 is a sectional view of an alternative embodiment of
an airfoil as may be described herein.
[0014] FIG. 6 is an expanded view of a portion of the airfoil of
FIG. 5.
[0015] FIG. 7 is a sectional view of an alternative embodiment of
an airfoil as may be described herein.
[0016] FIG. 8 is an expanded view of a portion of the airfoil of
FIG. 7.
[0017] FIG. 9 is an expanded view of an alternative embodiment of a
portion of the airfoil of FIG. 7.
[0018] FIG. 10 is a sectional view of an alternative embodiment of
an airfoil as may be described herein.
[0019] FIG. 11 is an expanded view of a portion of the airfoil of
FIG. 10.
DETAILED DESCRIPTION
[0020] Referring now to the drawings, in which like numerals refer
to like elements throughout the several views, FIG. 1 shows a
schematic view of gas turbine engine 10 as may be used herein. The
gas turbine engine 10 may include a compressor 15. The compressor
15 compresses an incoming flow of air 20. The compressor 15
delivers the compressed flow of air 20 to a combustor 25. The
combustor 25 mixes the compressed flow of air 20 with a pressurized
flow of fuel 30 and ignites the mixture to create a flow of
combustion gases 35. Although only a single combustor 25 is shown,
the gas turbine engine 10 may include any number of combustors 25.
The flow of combustion gases 35 is in turn delivered to a turbine
40. The flow of combustion gases 35 drives the turbine 40 so as to
produce mechanical work. The mechanical work produced in the
turbine 40 drives the compressor 15 via a shaft 45 and an external
load 50 such as an electrical generator and the like.
[0021] The gas turbine engine 10 may use natural gas, liquid fuels,
various types of syngas, and/or other types of fuels and
combinations thereof. The gas turbine engine 10 may be any one of a
number of different gas turbine engines offered by General Electric
Company of Schenectady, N.Y., including, but not limited to, those
such as a 7 or a 9 series heavy duty gas turbine engine and the
like. The gas turbine engine 10 may have different configurations
and may use other types of components. Other types of gas turbine
engines also may be used herein. Multiple gas turbine engines,
other types of turbines, and other types of power generation
equipment also may be used herein together.
[0022] FIG. 2 shows a sectional view of an example of a hot gas
path component 55. In this example, the hot gas path component 55
may be an airfoil 60. The airfoil 60 may be part of a nozzle, a
bucket, or any other type of hot gas path component 55 such as a
shroud and the like. The airfoil 60 may include an outer shell 65.
The airfoil 60 may extend from a pressure side 70 to a suction side
75. The airfoil 60 also may extend from a leading edge 80 to a
trailing edge 85. The airfoil 60 may have an overall aerodynamic
shape. The shell 65 may define a number of internal cooling
cavities 90 in communication with a number of film cooling holes 92
extending through the shell 65. A number of pin banks 94 also may
extend into the internal cooling cavities 90. A portion of the flow
of air 20 may be diverted from the compressor 15 so as to cool the
airfoil 60. The flow of air 20 may extend through the internal
cooling cavities 90 and may exit about the film cooling holes 92 or
elsewhere. The pin banks 94 may provide turbulence to the flow of
air 20. Many other types of hot gas path components 55 and airfoils
60 may be used. Likewise many different types of cooling schemes
and components also may be used.
[0023] FIGS. 3 and 4 show a hot gas path component 100 as may be
described herein. In this example, the hot gas path component 100
may be an airfoil 110. The airfoil 110 may be part of a nozzle or a
bucket. Other types of hot gas path components 100, such as a
shroud and the like, also may be used herein. The airfoil 110 may
include a shell 120. The shell 120 may have an interior surface 130
and an exterior surface 140. The interior surface 130 may have an
impingement sleeve 135, an impingement plate, or a similar type of
structure adjacent thereto. The shell 130 may extend from a
pressure side 150 to a suction side 160. Likewise, the airfoil 110
may extend from a leading edge 170 to a trailing edge 180 and may
define a substantially aerodynamic shape. The shell 120 may define
a number of internal cooling cavities 190 about the inner surface
130 thereof. A number of film cooling holes 200 may extend through
the shell 120. A number of pin banks 210 also may be positioned
within the internal cavities 190. Other components and other
configurations also may be used herein.
[0024] The airfoil 110 also may have a porous trailing edge section
220. The porous trailing edge section 220 may be filled with a
porous media 230. The porous media 230 may be formed from any
suitable porous material or materials having a matrix with a number
of voids therein. The porous media 230 may be formed from a metal
foam, a metal alloy foam, a ceramic foam, such as a ceramic matrix
composite foam, a carbon fiber foam, and similar types of porous
materials. Non-limiting examples of specific materials may include
Rene 142, Rene 195, MarM247, GTD111, GTD444, IN738, H282, H230,
IN625 and the like. The foam typically may be formed by mixing a
material, such as a metal, a ceramic, a carbon fiber, and the like
with another substance and then melting the substance so as to
leave the porous foam. The porous media 230 may be "printed" or
built up via a direct metal laser melting ("DMLM") process and the
like. Different types of sintering techniques and other types of
manufacturing techniques also may be used herein to create the
components herein. The porous media may vary in
porosity/permeability throughout based on optimizing the cooling
flow therethrough. For example, permeability may be lowest in
regions of highest heat load so that more coolant flows through
these regions as compared to regions where the heat load and the
coolant demand may be lower. A cooling medium 240 may flow through
the voids in the porous media 230 so as to facilitate cooling in a
highly efficient manner.
[0025] The porous trailing edge section 220 may be built directly
onto the airfoil 110 or the porous trailing edge section 220 may be
built separately and attached by any number of different
techniques. These techniques may include including brazing, arc
welding, high energy density welding such as laser welding and
electron beam welding, TLP bonding, diffusion bonding, or different
types of mechanical attachment. The buildup of the porous media 230
may be made over an existing component or as part of building a
component as a whole. The use of the DMLM process enables high heat
transfer through the porous media 230 while providing a high
quality joint between the airfoil 110 and the porous trailing edge
section 220. The porous trailing edge section 220 may have an
external sleeve 250 extending in whole or in part to direct the
flow to exit over only a certain section or sections of the
trailing edge. The external sleeve 250 may be a metallic component,
a thermal barrier coating, and the like. The coating may be an
aluminide and the like sprayed thereon. The cooling medium 240 thus
flows through the airfoil 110 and exits via the porous trailing
edge section 220 so as to cool the trailing edge 180. Other
components and other configurations may be used herein.
[0026] FIGS. 5 and 6 show a further example of a hot gas path
component 100. In this example, the hot gas path component 100 may
be an airfoil 260. The airfoil 260 may include a porous side
section 270 positioned on the suction side 160. The porous side
section 270 may include the porous media 230. Specifically the
porous media 230 may be built or attached into the shell 120 of the
airfoil 260 along the impingement sleeve 135 or about a grid on the
underlying structure. The porous media 230 may be aligned with the
shell so as to provide transpiration cooling and the like. The
cooling flow 240 thus may leak through the voids in the porous side
section 270. Any number of the porous side sections 270 may be used
herein in any size or shape. As above, the porosity and the
permeability may be varied throughout the porous piece so as to
optimize cooling usage. Other components and other configurations
may be used herein.
[0027] FIGS. 7-9 show a further example of a hot gas path component
100. In this example, the hot gas path component 100 may be an
airfoil 280. The airfoil 280 may include a porous external section
290 positioned on the suction side 160 or elsewhere along the
airfoil 280. Specifically, the porous external section 290 may
include a buildup of the porous media 230 on the shell 120.
Alternatively, the porous section may be built up separately and
attached by any number of different techniques including those
mentioned above. The shell 120 and the porous external section 290
may be in communication with the film cooling holes 200 extending
through the shell 120. As is shown in FIG. 8, an external sleeve
300 may be used over the porous media 230. A number of external
film cooling holes 310 may be positioned on the external sleeve
300. The external sleeve 300 may be metallic, a thermal barrier
coating, and the like. As is shown in FIG. 9, the external sleeve
300 may be optional such that the porous media 230 may not need any
type of covering. The external sleeve 300 may cover all, part, or
none of the porous media 230. The cooling flow 240 thus may flow
through the film cooling holes 200, the porous media 230 and/or the
external film cooling holes 310. The film cooling holes may be
partially formed in the porous media to improve flow distribution
into the porous media. Other components and other configurations
also may be used herein.
[0028] FIGS. 10 and 11 show a further embodiment of a hot gas path
component 100. In this example, the hot gas path component 100 may
be an airfoil 320. The airfoil 320 may include a porous internal
section 330. The porous internal section 330 may include a buildup
of the porous media 230 about the optional impingement sleeve 135
along the film cooling holes 200 or elsewhere within the shell 120
in whole or in part. Alternatively, the porous media may be built
separately and attached by a variety of methods such as those
described above. The permeability and porosity of the porous media
may vary as needed to optimize coolant usage. The cooling flow 240
thus may flow through the impingement sleeve 135, the porous media
230, and the film cooling holes 200. The film cooling holes may be
partially formed in the porous media to ensure an optimal film hole
shape for maximized film effectiveness. Other components and other
configurations may be used herein.
[0029] A number of alternative hot gas path components 100 also may
be used herein. Specifically, DMLM techniques may be used to build
both porous and solid features of the hot gas path component 100.
These DMLM techniques may be used to vary the porosities and/or the
permeability at different locations within the porous media 230.
The DMLM techniques thus can be used to build multiple different
discrete porous structures inside or outside thereof. Other methods
of making and attaching the porous material may be used as
well.
[0030] The hot gas path component 100 provides these integral
porous features so as to enable better heat transfer as well as
providing transpiration cooling. The use of the porous media 230
thus should reduce overall cooling load requirements. Specifically,
the porous media has been shown to have a significantly higher heat
transfer coefficient as compared to known airfoil materials as well
as provides superior control over the distribution of coolant over
the part. Using such a process on the hot gas path components in
multiple locations may increase heat transfer capability while
reducing cooling flow requirements. Moreover, the use of the DMLM
process provides the porous foam with an integral joint to the base
metal when built directly onto the part or as a whole with the
part. The DMLM process also provides control over the porosity and
the permeability throughout the part.
[0031] It should be apparent that the foregoing relates only to
certain embodiments of the present application and the resultant
patent. Numerous changes and modifications may be made herein by
one of ordinary skill in the art without departing from the general
spirit and scope of the invention as defined by the following
claims and the equivalents thereof.
* * * * *