JP6209058B2 - Component with a reentrant shaped cooling channel and manufacturing method - Google Patents

Description

  The present invention relates generally to gas turbine engines, and more particularly to microchannel cooling therein.

  In a gas turbine engine, air is compressed in a compressor and mixed with fuel in a combustor to generate hot combustion gases. From that gas, the energy in the high pressure turbine (HPT) that drives the compressor, and in the low pressure turbine (LPT) that drives the fan in aircraft turbofan engine applications or the external shaft in shipping and industrial applications. Is extracted.

  Engine efficiency increases with combustion gas temperature. However, the combustion gas heats various components along its flow path, which necessitates cooling of these components to achieve an acceptable long engine life. Usually, the hot gas path components are cooled by flowing air from the compressor. This cooling process reduces engine efficiency because the effluent gas is not used in the combustion process.

  Gas turbine engine cooling technology is mature and includes numerous patents for various aspects of cooling circuits and features in various hot gas path components. For example, the combustor includes radially outer and inner liners that require cooling during operation. The turbine nozzle includes a hollow vane supported between the outer and inner bands, which also requires cooling. Turbine rotor blades are hollow and typically contain cooling circuits therein that are surrounded by a turbine shroud that also requires cooling. The hot combustion gases are discharged through an exhaust port that is also lined and can be properly cooled.

  In all of these exemplary gas turbine engine components, high strength superalloy metal thin walls are typically used to reduce component weight and minimize its cooling needs. Various cooling circuits and features are tailored for these individual components in each corresponding environment within the engine. For example, a series of internal cooling passages or bend passages may be formed in the components of the hot gas path. Cooling fluid may be supplied from the plenum to these bent passages, and the cooling fluid may flow through the passages to cool the substrate of the hot gas path component and any associated coatings. However, this cooling strategy usually results in a relatively low heat transfer coefficient and a non-uniform component temperature profile.

  Microchannel cooling provides cooling as close as possible to the heated area, thereby reducing the temperature difference between the hot and cold sides of the primary load-bearing substrate material for a given heat transfer coefficient. This has the potential to significantly reduce the cooling requirements. However, current technology for forming microchannels uses sacrificial filling to prevent the coating from depositing within the microchannel and not only support the coating as it is deposited, but also the coating system After that, typically the sacrificial filling needs to be removed. However, filling the channel with temporary material, and subsequent material removal, both present potential problems with current microchannel processing techniques. For example, the filler must be compatible with the substrate and the coating, and must have sufficient strength with minimal shrinkage. Removal of the sacrificial filling is accompanied by potentially damaging steps such as extraction, etching or vaporization and usually takes a long time. Residual filler material is also a problem.

  Accordingly, it is desirable to provide a method for forming a cooling channel in a hot gas path component that further eliminates the need for fill and removal steps.

US Pat. No. 8,147,196

  One aspect of the present invention resides in a method for manufacturing a specific component. The component includes a substrate having at least one interior space. The method includes forming one or more grooves in the component, where each groove extends at least partially along the outer surface of the substrate and narrows at the opening. Thus, each groove includes a reentrant groove. The cross-sectional area A of each groove is in the range of about 2 to about 3 times the area of R = W * D, where W is the width of the reentrant groove opening and D is the reentrant The depth of the shape groove.

  Another aspect of the invention resides in a component that includes a substrate having an outer surface and an inner surface, the inner surface defining at least one interior space and the outer surface defining one or more grooves. Each groove extends at least partially along the surface of the substrate, and each groove comprises a reentrant-shaped groove by narrowing at the opening. The cross-sectional area A of each groove is in the range of about 2 to about 3 times the area of R = W * D, where W is the width of the reentrant groove opening and D is the reentrant The depth of the shape groove. The component further includes at least one coating deposited on at least a portion of the outer surface of the substrate, the groove and the coating together defining one or more reentrant shaped channels for cooling the component. To do.

  Yet another aspect of the invention resides in a component that includes a substrate having an outer surface and an inner surface, the inner surface defining at least one interior space. The component further includes at least one coating disposed on at least a portion of the surface of the substrate, the coating comprising: a structural coating deposited on the outer surface of the substrate; and an additional coating. Including at least one inner layer. One or more grooves are at least partially formed in the structural coating, each groove extending at least partially along the surface of the substrate and narrowing at its opening to narrow each groove. Includes reentrant shaped grooves. The cross-sectional area A of each groove is in the range of about 2 to about 3 times the area of R = W * D, where W is the width of the reentrant groove opening and D is the reentrant The depth of the shape groove. The groove and additional coating together define one or more reentrant shaped channels for cooling the component.

  These and other features, aspects, and advantages of the present invention will be better understood when the following detailed description is read with reference to the accompanying drawings, in which like symbols represent like parts throughout the views.

1 is a schematic view of a gas turbine system. 1 is a schematic cross-sectional view of an example airfoil structure with a reentrant cooling channel in accordance with aspects of the present invention. FIG. FIG. 6 shows a first pass of an abrasive liquid jet at an angle φ to form a reentrant groove. It is a figure which shows the 2nd passage of the abrasive liquid jet by the vertical angle 180-phi for forming a reentrant groove | channel. FIG. 6 shows an optional third pass of an abrasive liquid jet perpendicular to the groove for forming a reentrant groove. FIG. 3 is a schematic cross-sectional view of a portion of a cooling circuit with a reentrant cooling channel. FIG. 6 is a schematic cross-sectional view of an exemplary reentrant shaped groove. FIG. 6 is a schematic perspective view of three exemplary microchannels that extend partially along the surface of the substrate and pass coolant through each film cooling hole. FIG. 9 is a cross-sectional view of one exemplary microchannel of FIG. 8, showing the microchannel carrying coolant from an entry hole to a film cooling hole. FIG. 5 is a schematic cross-sectional view of five cooling channels AE having a cross-sectional area that varies from A = R to A = 2.33R. 1 is a schematic cross-sectional view of an exemplary tear-shaped cooling channel in accordance with aspects of the present invention. FIG. 11 shows the amount of coating (relative to the overall cross-sectional area of each cooling channel) deposited in the five cooling channels AE of FIG. 2 is a schematic cross-sectional view of an exemplary cooling channel having an asymmetric cross section. FIG. FIG. 3 is a cooling channel with permeable slots formed in a structural coating. FIG. 3 shows the amount of coating deposited in each of four circular cooling channels GJ (relative to the overall cross-sectional area of the cooling channel).

  The terms “first”, “second”, etc. herein do not imply any order, amount, or importance, but rather are used to distinguish one element from another. As used herein, the term “one” (“a” and “an”) does not imply a limit of quantity, but means that there is at least one thing mentioned. The modifier “about” used in connection with a quantity includes the stated value and has a meaning indicated by the context (eg, including the degree of error associated with the measurement of the particular quantity). Further, the term “combination” includes blends, blends, alloys, reaction products, and the like.

  Further, as used herein, the (s) (suffix “(s)”) typically includes both the singular and plural of the terms it modifies, and thus one or more of the terms (E.g., "pass hole" may include one or more pass holes unless otherwise specified). References throughout this specification to “one embodiment,” “another embodiment,” “an embodiment,” and the like include certain elements (eg, features, structures, and / or features) described in connection with that embodiment. Characteristic) is included in at least one embodiment described herein and may or may not be present in other embodiments. Similarly, reference to “a particular configuration” includes a particular element (eg, feature, structure, and / or property) described in connection with that configuration within at least one configuration described herein, and others This means that it may or may not be included in the configuration. Further, it is to be understood that the inventive features described may be combined in any suitable manner in the various embodiments and configurations.

  FIG. 1 is a schematic diagram of a gas turbine system 10. The system 10 may include one or more compressors 12, a combustor 14, a turbine 16, and a fuel nozzle 20. The compressor 12 and the turbine 16 may be connected by one or more shafts 18.

  The gas turbine system 10 may include several hot gas path components 100. A hot gas path component is any component of the system 10 that is at least partially exposed to a high temperature gas flow through the system 10. For example, bucket assemblies (also known as blades or blade assemblies), nozzle assemblies (also known as vanes or vane assemblies), shroud assemblies, transition pieces, retaining rings, and turbine exhaust components are all hot gas path components. It is. However, it should be understood that the hot gas path component 100 of the present invention is not limited to the above examples, and may be any component that is at least partially exposed to a high temperature gas flow. Further, it is understood that the hot gas path component 100 of the present disclosure is not limited to components of the gas turbine system 10 and may be any mechanical device or component thereof that is exposed to high temperature flow. I want to be.

  When the hot gas path component 100 is exposed to a hot gas flow, the hot gas path component 100 is heated by the hot gas flow to a temperature at which the hot gas path component 100 is significantly degraded or failed. There is a possibility to reach. Thus, in order to allow the system 10 to operate with the high temperature hot gas flow necessary to achieve the desired efficiency, performance and / or lifetime of the system 10, the hot gas path components 100 A cooling system is needed.

  In general, the cooling system of the present disclosure includes a series of small channels or microchannels formed on the surface of the hot gas path component 100. For industrial scale power generation turbine components, the dimensions of the “small” or “micro” channel are considered to encompass approximate depths and widths in the range of 0.25 mm to 1.5 mm, while the aircraft industry scale The turbine component channel dimensions will encompass an approximate depth and width in the range of 0.1 mm to 0.5 mm. The hot gas path components may be provided with a protective coating. A cooling fluid may be supplied from the plenum to the channel, and the cooling fluid may flow through the channel to cool the components of the hot gas path.

The manufacturing method will be described with reference to FIGS. For example, as shown in FIG. 2, the method is directed to manufacturing a component 100 that includes a substrate 110 having at least one interior space 114. The substrate 110 is typically cast prior to forming the groove (s) 132. Melvin R., which is incorporated herein by reference in its entirety. As discussed in Jackson et al., US Pat. No. 5,626,462, “Double-wall airfoil”, substrate 110 may be formed from any suitable material. Depending on the intended use for component 100, this can include Ni-based, Co-based, and Fe-based superalloys. Ni-based superalloys may include both γ and γ ′ phases, and in particular may include both γ and γ ′ phases in which the γ ′ phase occupies at least 40% of the volume of the superalloy. . Such alloys are known to be advantageous due to the combination of desirable properties including high temperature strength and high temperature creep resistance. The substrate material may also include NiAl intermetallic alloys because these alloys are also excellent for high temperature strength and high temperature creep resistance, which is also convenient for use in aircraft turbine engine applications. This is because it is known to have a combination of characteristics. In the case of the Nb main component alloy, a coated Nb main component alloy having excellent anti-oxidation property is preferable, and in particular, Nb- (27-40) Ti- (4.5-10.5) Al- (4. Alloys containing 5-7.9) Cr- (1.5-5.5) Hf- (0-6) V are preferred, where the compositional range units are atomic percent. The substrate material may also include Nb-based alloys that include at least one secondary phase, such as Nb-containing intermetallics including silicides, carbides, or borides. Such an alloy is a composite of a ductile phase (ie, a Nb-based alloy) and a reinforcing phase (ie, an Nb-containing intermetallic compound). In another configuration, the base material includes a molybdenum-based alloy such as a molybdenum-based alloy (solid solution) with a second phase of Mo ₅ SiB ₂ and / or Mo ₃ Si. In another configuration, the substrate material comprises a ceramic matrix composite (CMC), such as a SiC matrix reinforced with silicon carbide (SiC) fibers. As another configuration, the base material includes an intermetallic compound containing TiAl as a main component.

  With reference now to FIGS. 3, 4, and 6-8, the manufacturing method includes forming one or more grooves 132 in the component 100. As shown, for example in FIG. 8, each groove 132 extends at least partially along the outer surface 112 of the substrate 110 and narrows at its opening 136 such that each groove 132 is a reentrant-shaped groove. 132. With respect to the configuration shown in FIG. 3, the grooves flow coolant through each film cooling hole 172. Exemplary techniques for forming the grooves 132 include, but are not limited to, abrasive liquid jets, plunge electrolytic machining (ECM), electrical discharge machining (EDM), electrical discharge machining with rotating electrodes (milling EDM). And laser processing. Exemplary laser processing techniques are described in U.S. Patent Application Publication No. 12 / 697,005, "Process and system forming shaped air holes", filed January 29, 2010, assigned to the assignee of the present invention. Which is incorporated herein by reference in its entirety. Exemplary EDM techniques are described in U.S. Patent Application Publication No. 12 / 790,675, filed May 28, 2010, "Articles which include chevrons film cooling holes, and related processes", assigned to the assignee of the present invention. Which is incorporated herein by reference in its entirety. In certain processes, the grooves 132 are formed using an abrasive liquid jet, which will be discussed in more detail below with reference to FIGS.

  Referring now to FIGS. 7 and 10, for example, the cross-sectional area A of each groove is in the range of about 2 to about 3 times the area of R = W * D, where W is the reentrant shape. The width of the opening 136 of the groove 132, and D is the depth of the reentrant groove 132. In other words, the area R is a cross-sectional area of an imaginary rectangular groove having the same width and the same depth as the reentrant groove in the opening. For example, channel A and channel B in FIG. 10 have an area of 2.33R and 2R, respectively. Advantageously, a cooling channel having a cross-sectional area A that is in the range of about 2 to about 3 times the area of R = W * D can cause very little coating to be deposited in the channel during the coating process. There is no need to use sacrificial filling.

  In a particular configuration, each groove 132 is symmetric about the centerline. As used herein, “symmetric” should be understood to encompass minor deviations in the groove profile caused by machining accuracy. For example, the grooves shown in FIGS. 6 to 8 and FIGS. 10 to 12 are symmetrical with respect to the center line. The groove may have a flat base 134 as shown in FIGS. 6-8 and 10. In other configurations, the base 134 of the groove 132 may be circular. For example, the groove may have a teardrop shape as shown in FIG. Advantageously, channels that are essentially symmetrical about the centerline have a relatively larger cross-sectional area (same depth and same opening width) than asymmetric channels such as those shown in FIG. in the case of).

  However, in other configurations, each groove 132 may have an asymmetric cross section, for example as shown in FIG. Asymmetric grooves are discussed in US Patent Application Publication No. 13 / 664,458, assigned to the assignee of the present invention, which is incorporated herein by reference in its entirety. Asymmetric cross-sections may be necessary in areas where component machining is difficult or to accommodate other functions and / or constraints within the component.

  As pointed out above, the grooves 132 can be formed using several techniques. With respect to the exemplary process shown in FIGS. 3 and 4, each groove 132 is formed by directing an abrasive liquid jet 160 to the outer surface 112 of the substrate 110. With respect to the process shown in FIGS. 3 and 4, by directing the abrasive liquid jet 160 at a horizontal angle relative to the surface 112 of the substrate 110 during one or more passes of the abrasive liquid jet 160, At least one groove 132 is formed.

  An exemplary abrasive liquid jet grinding process and system is described in US Patent Application Publication No. 12 / 790,675, filed May 28, 2010, “Articles who include chevron film, assigned to the assignee of the present invention. Cooling holes, and related processes ", which is incorporated herein by reference in its entirety. As described in US patent application Ser. No. 12 / 790,675, abrasive liquid jet processing typically involves a high velocity stream of abrasive particles (eg, abrasive “grit”) suspended in a high pressure water stream. Is used. The pressure of the liquid can vary greatly, but is often in the range of about 35-620 MPa. Several abrasive materials such as garnet, aluminum oxide, silicon carbide, and glass beads can be used. Advantageously, the ability of the abrasive liquid jet processing technique facilitates material removal at various depth stages while controlling the shape of the feature being processed.

  In addition, the water jet system may include a multi-axis computer numerical control (CNC) unit 210 (FIG. 4), as described in US Patent Application Publication No. 12 / 790,675. CNC systems themselves are known in the art and are described, for example, in US Patent Application Publication No. 1005/0013926 (S. Rutkowski et al.), Which is incorporated herein by reference in its entirety. The CNC system allows movement of the cutting tool along the X, Y, and Z axes and some of the tilt axes.

  In addition, forming the groove 132 may further include performing at least one additional pass, in which the abrasive liquid jet 160 is at a horizontal angle to the outer surface 112 of the substrate 110. And is directed to the base 134 of the groove 132 at one or more angles between the directions 52 substantially perpendicular to this plane, thereby removing material from the base 134 of the groove 132 (see FIG. 5). . Note that as used herein, the “base” is the bottom of the groove and may be curved (FIG. 11) or flat (FIG. 10).

  With reference now to FIGS. 8 and 9, the manufacturing method may further include forming one or more entry holes 140 in the substrate 110. As shown, for example, in FIG. 14, each entry hole 140 connects a respective groove 132 with a respective interior space 114 in fluid communication. It should be noted that the holes 140 shown in FIG. 8 are separate holes located in the cross-sectional view shown and do not extend through the substrate along the length of the groove 132.

  The internal entry holes 140 that supply each groove may be ground as either a straight hole of constant cross-section, a shaped (eg, elliptical) hole, or a converging or spreading hole (not shown). . Methods for forming access holes are described in U.S. Patent Application Publication No. 13 / 210,697 (Ronald S. Bunker et al.), “Components with cooling of channels and methods of manufacture”, assigned to the assignee of the present invention. Which is incorporated herein by reference in its entirety. In certain processes, the entry hole 140 may be formed using an abrasive liquid jet, as described above. As indicated, abrasive liquid jet processing advantageously facilitates material removal at various depth stages while controlling the shape of the feature being processed. This also makes it possible to grind the internal entry hole 140 that feeds the channel into the shape indicated above, i.e. a straight hole of constant cross-section, a shaped hole, or a hole that converges or spreads.

  In certain configurations, the grooves 132 are formed in the outer surface 112 of the substrate 110. See, for example, FIGS. 8 and 9. With reference now to FIGS. 8, 9, and 12, the manufacturing method may further include depositing a coating 150 on at least a portion of the surface 112 of the substrate 110. In such a configuration, the groove 132 and the coating 150 together define one or more reentrant shaped channels 130 for cooling the component 100. The coating 150 includes a structural coating layer and may optionally include additional coating layers. The coating layer can be deposited using a variety of techniques. In certain processes, the structural coating may be deposited by performing ion plasma deposition (also known in the art as cathodic arc deposition). An example of an apparatus and method for ion plasma deposition is provided in Weaver et al., US Patent Application Publication No. 2008/0138529, “Method and Apparatus for Cathodic Arcion Plasma Deposition”, assigned to the assignee of the present invention. Which is incorporated herein by reference in its entirety. Briefly, ion plasma deposition involves placing a consumable cathode in a vacuum chamber having a composition to create a desired coating material, supplying a substrate 110 into a vacuum environment, and applying current to the cathode. To form a cathodic arc on the cathode surface, resulting in arc-induced erosion of the coating material from the cathode surface, and depositing the coating material from the cathode on the substrate surface 112 including.

Non-limiting examples of structural coatings deposited using ion plasma deposition are described in Jackson et al. US Pat. No. 5,626,462, “Double-wall airfoil”. In some hot gas path components 100, the structural coating 54 includes a nickel-based or cobalt-based alloy, and more specifically, a superalloy or a (Ni, Co) CrAlY alloy. If the substrate material is a Ni-based superalloy containing both a γ phase and a γ ′ phase, the structural coating includes a material composition similar to that discussed in US Pat. No. 5,626,462. But you can. Further, as a superalloy, the structural coating 54 may include a composition based on a γ′-Ni ₃ Al alloy.

  More generally, it is believed that the composition of the structural coating is determined by the composition of the underlying substrate. For example, in a CMC substrate such as a SiC matrix reinforced with silicon carbide (SiC) fibers, the structural coating is typically considered to comprise silicon.

  In other processing configurations, the structural coating is deposited by performing at least one of a thermal spray process and a cold spray process. For example, the thermal spray process may include combustion spray or plasma spray, the combustion spray may include high velocity oxygen fuel spray (HVOF) or high velocity air fuel spray (HVAF), and the plasma spray may be atmospheric pressure (air or inert gas). Etc.) Plasma spraying or reduced pressure plasma spraying (also known as LPPS, vacuum plasma spraying or VPS). In one non-limiting example, the (Ni, Co) CrAlY coating is deposited by HVOF or HYAF. Other exemplary techniques for depositing the structural coating include, but are not limited to, sputtering, electron beam physical vapor deposition, entrapment plating, and electroplating.

  As discussed in US Patent Application Publication No. 12 / 943,624 (Bunker et al.), “Components with re-entrant shaped cooling channels and methods of manufacture”, current techniques for forming microchannels are typical. Uses sacrificial filling to prevent the coating from depositing in the microchannel and not only supports the coating as it is deposited, but also removes the sacrificial filling after the coating system is deposited There is a need to. However, both channel filling with temporary material and subsequent removal of the material present potential problems with current microchannel processing technology. For example, the filler needs to be compatible with the substrate and the coating, and should have sufficient strength with minimal shrinkage. Removal of the sacrificial filling is accompanied by potentially damaging steps such as extraction, etching or vaporization and usually takes a long time. Residual filler material is also a problem.

  Forming a channel with a reentrant geometry and a small top face opening width helps keep the coating deposits out of the channel. However, if no filling is utilized, the channel opening width may not be sufficient to keep the coating material deposit out of the channel. FIG. 12 depicts exemplary fill ratios for channels with different cross-sectional areas A. As used herein, “fill ratio” is the fraction of the channel area occupied by the coating deposited in the channel (shown by reference numeral 162 in FIG. 12). For example, if no coating is deposited in the channel, the fill ratio is zero. Similarly, if the entire cross-sectional area of the channel is filled with the deposited coating, the filling ratio is 100%. Note that in the example shown in FIG. 12, channels A-E have equal opening widths. However, as shown in FIG. 12, a significant portion of a square channel is filled with a coating, whereas a reentrant shaped channel progresses from D to A as the channel profile becomes more reentrant. ) With progressively less coating deposits as a fraction of the channel cross-sectional area. A smaller aperture width approaching zero will help keep the coating deposit out of the channel, but this does not explain the properties found herein.

  Without being bound by any particular theory, it is believed that directed impulsive sprays trap the air in the channel space and pressurize to some extent (possibly by heating), and this trapped air is the coating Acts as a back pressure and blockage that refuses particles (most or all) to enter the interior of the channel. Such a physical explanation for the observed phenomenon is particularly applicable to any processing performed in air, such as thermal spray coating. Impinging sprays have an effective diameter much larger than the size of the channel opening, but this is not sufficient to provide the effect observed alone. Since sufficient internal space of pressurized disturbing air is required and this air can also circulate in this space, it will break a range of desirable and necessary ratio channels that provide the observed results. It becomes an area.

  In certain processes, the fill ratio of the coating deposited in each groove is less than 20 percent, and more particularly less than 10 percent. See, for example, channel A and channel B in FIG. 12 and channel G in FIG. Briefly, FIG. 15 shows the amount of coating (relative to the overall cross-sectional area of each cooling channel) deposited in the four circular cooling channels GJ. As can be seen in FIG. 15, A> 2 for cooling channel G, A-2 for cooling channel H, and A <2R for cooling channels I and J. The amount of coating 162 deposited in channels GJ is approximately the same in each cooling channel, but the percentage of cross-sectional area occupied by coating deposit 162 is less than that of cooling channel J. G is much smaller. Advantageously, having a relatively unblocked channel improves the cooling flow through the channel.

  Referring now to FIG. 14, the coating includes at least one structural coating 54 and an additional coating 56, and each groove 132 is at least partially formed in the structural coating 54. . In a particular configuration (FIG. 14), the groove is completely formed in the structural coating 54. However, in other configurations (not shown), the grooves extend through the structural coating to the substrate 110.

  Advantageously, the method described above facilitates coating the cooled component without using sacrificial filling. By bridging opening 136 with coating 150 without the use of sacrificial filling, two major processing steps (filling and extraction steps) associated with conventional channel formation techniques can be eliminated.

  Embodiments of the component 100 of the present invention are described with reference to FIGS. As shown in FIG. 2, the component 100 includes a substrate 110 having an outer surface 112 and an inner surface 116. The substrate 110 has been described above. As shown in FIG. 2, for example, the inner surface 116 defines at least one interior space 114. As shown in FIG. 8, the outer surface 112 defines one or more grooves 132. Each groove 132 extends at least partially along the surface 112 of the substrate 110 and narrows at its opening 136 such that each groove 132 is a reentrant groove 132. Referring now to FIGS. 7 and 10, for example, the cross-sectional area A of each groove is in the range of about 2 to about 3 times the area of R = W * D, where W is the reentrant shape. The width of the opening 136 of the groove 132, and D is the depth of the reentrant groove 132. As pointed out above, the area R is the cross-sectional area of an imaginary square groove having the same width and the same depth as the reentrant groove in the opening.

  As shown in FIG. 8, the component 100 further includes at least one coating 150 disposed on at least a portion of the outer surface 112 of the substrate 110. The coating 150 has been described above and can have one or more coating layers having a single or different composition. As shown in FIG. 8, for example, the groove 132 and the coating 150 together define one or more reentrant shaped channels 130 for cooling the component 100. In certain configurations (FIGS. 8 and 12), the coating 150 completely bridges each groove 132 so that the coating 150 seals each microchannel 130. However, in other configurations (see, eg, FIG. 14, which shows a breathable gap 144 when a groove is formed in the structural coating layer 54), the coating 150 has one or The coating 150 does not completely bridge each groove 132 to define a plurality of breathable gaps 144.

  In a particular configuration, each groove 132 is symmetric about the centerline. As pointed out above, “symmetric” should be understood to encompass minor deviations in the groove profile caused by machining accuracy. For example, the grooves shown in FIGS. 6 to 8 and FIGS. 10 to 12 are symmetrical with respect to the center line. For example, as shown in FIGS. 6 to 8, the groove may have a flat base. In other configurations, the base 134 of the groove 132 may be circular. For example, the groove may have a teardrop shape as shown in FIG.

  However, in other configurations, each groove 132 may have an asymmetric cross section, for example as shown in FIG. As pointed out above, asymmetric grooves are discussed in US Patent Application Publication No. 13 / 664,458, assigned to the assignee of the present invention.

  With reference now to FIGS. 8 and 9, one or more entry holes 140 may be formed in the substrate 110. As shown in FIG. 14, for example, each entry hole connects a respective groove 132 with a respective interior space 114 in fluid communication. As noted above, the holes 140 shown in FIG. 8 are separate holes arranged in the cross-sectional view shown and do not extend through the substrate along the length of the groove 132. The entry holes are described above with reference to FIGS.

  In certain configurations, the fill ratio of the coating deposited in each groove is less than 20 percent, and more particularly less than 10 percent. See, for example, channel A and channel B in FIG. 12 and channel G in FIG. As pointed out above, “fill ratio” is the percentage of the area of the channel occupied by the coating deposited in the channel. Advantageously, having a relatively low fill ratio allows the channel to carry sufficient coolant for a given channel cross-sectional area.

  The advantages of the components described above include an improved cooling effect that reduces manufacturing costs by eliminating the two expensive processing steps (filling and extraction steps) associated with the coating of cooled components as in the prior art. included.

  Another component 100 embodiment of the present invention is described with reference to FIGS. As shown in FIG. 2, the component 100 includes a substrate 110 having an outer surface 112 and an inner surface 116. As shown in FIG. 2, for example, the inner surface 116 defines at least one interior space 114. The substrate 110 has been described above.

  As shown in FIG. 14, the component 100 further includes at least one coating 150 disposed on at least a portion of the surface 112 of the substrate 110. As shown in FIG. 14, the coating 150 includes a structural coating 54 disposed on the outer surface 112 of the substrate 110 and at least one inner layer of an additional coating 56. The additional coating 56 may have one or more different coating layers. For example, the additional coating 56 may include additional structural coatings and / or optional additional coating layers, such as adhesive coatings, thermal barrier coatings (TBCs), and antioxidant coatings. In certain configurations, the additional coating 56 may include an outer structural coating layer (also denoted by reference numeral 56). In certain configurations, structural coating 54 and additional coating 56 are in the range of 0.1 to 2.0 millimeters, more specifically in the range of 0.2 to 1 millimeter, and even more specifically in industrial components. Having a combined thickness in the range of 0.2-0.5 millimeters. For aircraft components, this range is typically 0.1 to 0.25 millimeters. However, other thicknesses may be utilized depending on the requirements for the particular component 100.

  In the exemplary configuration shown in FIG. 14, the groove 132 is at least partially formed in the structural coating 54. Each groove 132 extends at least partially along the surface 112 of the substrate 110 and narrows at its opening 136 so that each groove 132 is a reentrant groove (132). (Thus, the extension of the groove along the base material is the same as the structure shown in FIG. 8 when the groove is formed in the base material.) Examined above with reference to FIG. As such, the cross-sectional area A of each groove is in the range of about 2 to about 3 times the area of R = W * D, where W is the opening 136 of the reentrant groove (132). The width is D, and D is the depth of the reentrant groove 132. For example, channel A and channel B in FIG. 10 have an area of 2.33R and 2R, respectively. As shown in FIG. 14, the groove 132 and additional coating 56 together define one or more reentrant shaped channels 130 for cooling the component 100.

  In certain configurations, each groove 132 is completely disposed within the structural coating 54. See, for example, FIG. In other configurations (not explicitly shown), each groove 132 extends through the structural coating 54 to the substrate 110. In certain configurations, the additional coating 56 completely bridges each groove 132 so that the additional coating 56 seals each microchannel 130 (eg, when a groove is formed in the substrate). (See FIG. 6). However, in other configurations, the additional coating 56 defines one or more breathable gaps 144 so that the additional coating 150 does not completely bridge each groove 132 (eg, FIG. 14). See).

  The groove geometry is described above. In a particular configuration, each groove 132 is symmetric about the centerline. For example, the grooves shown in FIGS. 6 to 8 and FIGS. 10 to 12 are symmetrical with respect to the center line. As pointed out above, the groove may have a flat base 134 as shown, for example, in FIG. In other configurations, the base 134 of the groove 132 may be circular. For example, the groove may have a teardrop shape as shown in FIG.

  However, in other configurations, each groove 132 may have an asymmetric cross section, for example as shown in FIG. As pointed out above, asymmetric grooves are discussed in US Patent Application Publication No. 13 / 664,458, assigned to the assignee of the present invention.

  One or more entry holes 140 may be formed in the substrate 110 as described above with reference to FIGS. 8 and 9. As shown in FIG. 14, for example, each entry hole connects a respective groove 132 with a respective interior space 114 in fluid communication. As noted above, the holes 140 shown in FIG. 8 are separate holes arranged in the cross-sectional view shown and do not extend through the substrate along the length of the groove 132.

  In certain configurations, the fill ratio of the coating deposited in each groove is less than 20 percent, and more particularly less than 10 percent. See, for example, channel A and channel B in FIG. 12 and channel G in FIG. As pointed out above, “fill ratio” is the percentage of the area of the channel occupied by the coating deposited in the channel.

  The advantages of the manufacturing methods and components described above include improved cooling and manufacturing costs associated with eliminating the two expensive processing steps (filling and extraction steps) associated with coating the component to be cooled. Includes a decline.

10 Gas turbine system 12 Compressor 14 Combustor 16 Turbine 18 Shaft 20 Fuel nozzle 52 Vertical direction 54 Structural coating 56 Additional coating (s) (outer structural coating)
100 hot gas path components 110 substrate 112 substrate outer surface 114 interior space 116 substrate inner surface 130 cooling channel 132 groove (s) 134 groove base 136 groove opening 140 (one or Multiple entry holes 144 Breathable gap (s) 146 Groove top 150 Additional coating 160 Abrasive liquid jet 162 Coating deposit 172 Film cooling hole D Groove depth W Groove opening width

Claims (22)

A method of manufacturing a component comprising a substrate having at least one internal space, comprising the step of forming one or more grooves in the component,
Each groove includes a base that is rounded to define a tear-shaped groove as a whole, and extends at least partially along the outer surface of the substrate and narrows at its opening to narrow each groove. Includes reentrant-shaped grooves,
The cross-sectional area A of each groove is in the range of about 2 to about 3 times the area of R = W * D, where W is the width of the opening of the reentrant groove and D is The method is a depth of the reentrant groove.   The method of claim 1, wherein each groove is symmetric about a centerline.   The method of claim 1, wherein each groove has an asymmetric cross section.   2. The method of claim 1, further comprising forming one or more entry holes in the substrate, each entry hole connecting one of the grooves in fluid communication with the respective interior space. The method described in 1.   The method of claim 1, wherein the groove is formed in the outer surface of the substrate.   Further comprising disposing a coating on at least a portion of the surface of the substrate, the groove and the coating together defining one or more reentrant shaped channels for cooling the component. Item 2. The method according to Item 1.   The method of claim 6, wherein a fill ratio of the coating deposited in each groove is less than 20 percent.   The method of claim 7, wherein the fill ratio of the coating deposited in each groove is less than 10 percent.   The method of claim 6, wherein the coating comprises at least one structural coating and an additional coating, and each groove is at least partially formed in the structural coating. A substrate having an outer surface and an inner surface, wherein the inner surface defines at least one interior space, the outer surface defines one or more grooves, each groove being generally a tear Including a base rounded to define a groove in the mold, and extending at least partially along the surface of the substrate, each groove including a reentrant-shaped groove by narrowing at the opening; The cross-sectional area A of each groove is in the range of about 2 to about 3 times the area of R = W * D, where W is the width of the opening of the reentrant groove and D is A base material that is the depth of the reentrant groove;
At least one coating disposed on at least a portion of the outer surface of the substrate, the groove and the coating together defining one or more reentrant shaped channels for cooling a component; A component comprising a coating.   The component of claim 10, wherein each groove is symmetric about a centerline.   The component of claim 10, wherein each groove has an asymmetric cross section.   The component of claim 10, wherein one or more entry holes are formed in the substrate, each entry hole connecting the respective groove in fluid communication with the respective interior space.   The component of claim 10, wherein a fill ratio of the coating deposited in each groove is less than 20 percent.   The method of claim 14, wherein the coating is disposed by performing a thermal spray process.   The component of claim 14, wherein the fill ratio of the coating deposited in each groove is less than 10 percent. A substrate having an outer surface and an inner surface, the inner surface defining at least one interior space;
At least one coating disposed on at least a portion of the surface of the substrate, the structural coating disposed on the outer surface of the substrate, and at least one inner layer of an additional coating. A coating with
One or more grooves are at least partially formed in the structural coating, each groove including a base that is rounded to define a generally tear-shaped groove, and the substrate Each groove includes a reentrant-shaped groove by extending at least partially along the surface of the
The cross-sectional area A of each groove is in the range of about 2 to about 3 times the area of R = W * D, where W is the width of the opening of the reentrant groove and D is , The depth of the reentrant groove,
The component wherein the groove and the additional coating together define one or more reentrant shaped channels for cooling the component.   The component of claim 17, wherein each groove is symmetric about a centerline.   The component of claim 17, wherein each groove has an asymmetric cross section.   18. The component of claim 17, wherein one or more entry holes are formed in the substrate, each entry hole connecting the respective groove in fluid communication with the respective interior space.   The component of claim 17, wherein a fill ratio of the coating deposited in each groove is less than 20 percent. The component of claim 21, wherein the fill ratio of the coating deposited in each groove is less than 10 percent.