VARIABLE COOLANT CHANNEL HEAT EXCHANGER FOR COMBUSTOR WALLS

STATEMENT OF GOVERNMENT INTEREST

[0001]This invention was made with government support under Contract No. FA8650-22-D-2009 awarded by the United States Air Force. The government has certain rights in the invention.

BACKGROUND

[0002]The invention relates to cooling channels for high-temperature components and, more particularly, to cooling channels with designs for optimizing a trade-off between cooling effectiveness and pressure loss.

[0003]Active cooling is necessary for many components exposed to high temperature environments to maintain the component material within an acceptable temperature range necessary for achieving component life and mechanical performance. Cooling channels, internal passages, and other cooling features reduce component temperatures. The performance of these cooling features can be increased with increased fluid flow and fluid pressure for a given cooling fluid. However, increased fluid flow and fluid pressure can lead to increased pressure loss associated with flow through the cooling feature. Since cooling features with high pressure loss can contribute increased operational costs and/or decreased efficiency, cooling features with optimum cooling performance and minimal pressure loss are highly desirable.

SUMMARY

[0004]A component according to an example embodiment of this disclosure includes a wall and a passage. The wall bounds an interior region and extends along an axis from a first end to a second end of the component. The passage extends within the wall between the first end and the second end. The passage includes an undulating profile comprising a plurality of undulations and extends along an extension axis. The undulating profile includes a first period measured along the extension axis between a first pair of adjacent undulations that is different from a second period measured along the extension axis between a second pair of adjacent undulations.

[0005]A method of manufacturing a component according to another embodiment of this disclosure includes forming a passage extending through a wall of the component having an undulating profile, the undulating profile having at least a first period and a second period greater than the first period, wherein the first period coincides with a first zone of the component configured to have higher heat flux than a second zone coinciding with the first period.

BRIEF DESCRIPTION OF THE DRAWINGS

[0006]FIG. 1 is a cross-sectional view of an example component with variable heat load.

[0007]FIG. 2 is a schematic view of a sinusoidal cooling passage profile with variable period.

[0008]FIG. 3 is a partial developed cross-sectional view along line B-B of FIG. 1 depicting sinusoidal cooling passages with variable period.

DETAILED DESCRIPTION

[0009]As disclosed herein is a component that includes an internal cooling passage with an undulating profile. The undulating profile can vary along an extension axis of the passage based on heat flux into the component. Specifically, zones of component with higher heat flux can coincide with portions of the passage with high undulation frequency relative to zones of component with lower heat flux, which coincide with portions of the passage that have low undulation frequency. Portions of the passage with relatively high undulation frequency have less distance between adjacent undulations of the profile and greater pressure drop than portions of the passage with relatively low undulation frequency. In this way, the frequency of the undulation profile is variable to provide greater cooling density within zones of the component with higher heat flux, leaving relatively lower heat flux zones with less pressure drop than an analogous undulation passage with a constant frequency.

[0010]FIG. 1 is a cross-sectional view of component 10 taken along axis A. Component 10 includes wall 12 and passage 14 (see FIG. 2 and FIG. 3). Wall 12 is bound by interior surface 16 and exterior surface 18 and extends about axis A to bound interior region 20, which is radially inward of wall relative to axis A. Wall 12 can include linear portions, convergent portions, and/or divergent portions, which extend along axis A. For example, wall 12 can include one or more portions extending along axis A that have a cylindrical and/or polynomial cross-section normal to axis A. Converging and/or diverging portions of wall 12 can include frustoconical sections that linearly converge or diverge towards or away from axis A respectively. In other examples, converging and/or diverging portions can be contoured to form a convex or concave profile when viewed in a cross-section containing axis A.

[0011]Passage 14 extends within wall 12 along axis A between first end 10A and second end 10B of wall 12. Passage 14 can be proximate interior surface 16 of wall 12 in order to increase the cooling of component 10 while other examples of component can include passage 14 that extends through a medial section of component 10, or is proximate to an exterior surface of component 10. Some examples of component 10 can have multiple passages 14 within wall 12 spaced circumferentially about axis A.

[0012]In each example, at least some of passages 14 include an undulating profile formed by a plurality of undulations along extension axis E of passage 14. In some examples, the undulations have constant amplitude measured relative to extension axis E while other examples of passage 14 can include undulations with variable amplitude in which a maximum distance between extension axis E and each undulation varies along extension axis E. The period of the undulating profile is described as the linear distance between adjacent undulations measured at the intersection of the undulating profile with extension axis E in which an undulation is an S-shaped portion of the profile that includes positive amplitude and negative amplitude portions of the profile relative to extension axis E. The undulating profile can include variable period such that the undulating profile has a variable frequency. For example, passage 14 can include portions with an undulating profile characterized by a smaller period (i.e., higher frequency) than portions with a larger period (i.e., lower frequency). In another example, passage 14 can include a continuously varying period (i.e., a continuously varying frequency) along the extension of passage 14. The amplitude and period of undulating profile can be described as sinusoidal in some examples.

[0013]Passages 14 can extend longitudinally through component 10 such that extension axes E of each passage 14 can be parallel to component axis A as indicated by dashed lines EA. In other examples, passages 14 can extend circumferentially such that extension axes extend about component axis A as indicated by dashed lines EB. In yet other examples, passages 14 can extend helically through component 10 such that extension axes form a spiral about component axis A as indicated by dashed lines EC.

[0014]Some examples of component 10 are produced using additive manufacturing (e.g., powder bed fusion) or a casting process such that passages 14 are formed within a monolithic wall. In other examples, component 10 includes an interior plate that is joined to and conforms to wall 12 to enclose passages 14, which are formed using one or more subtractive manufacturing processes (e.g., conventional milling, electric discharge machine, and the like). The interior plate can be joined to wall 12 via a brazing process for example and forms interior surface 16 of component 10 in these examples.

[0015]Component 10 can include end flanges 24A and 24B at opposing ends 10A and 10B of component 10 relative to axis A. Flange 24A and flange 24B are formed by thickened portions of wall 12, which can be used to increase radial stiffness of component 10 and/or to attach component 10 to adjacent components or other structural support. In further examples, cavities within flange 24A and flange 24B can form inlet plenum 26 and outlet plenum 28, respectively. Inlet plenum 26 extends circumferentially, at least partially, about axis A to fluidly connect one or more passages 14 to one or more inlet passages 14 extending through wall 12 at end 10A with respect to axis A. Outlet plenum 28 extends circumferentially, at least partially, about axis A to fluidly connect one or more passages 14 to one or more outlet passages 14 extending through wall 12 at end 10B with respect to axis A. In other examples, passages 14 intersect end 10A, end 10B, or both to communicate with an inlet plenum and/or outlet plenum that is external to component 10.

[0016]As shown in FIG. 1, component 10 is a combustor 30 with wall 12 that extends linearly through at least first zone 32 and second zone 34 and converges towards axis A in third zone 36. Passage 14 extends between first end 10A and second end 10B through first zone 32, second zone 34, and third zone 36. Within the first zone 32 and third zone 36, passage 14 includes a undulating profile with a first period and third period, respectively, that are less than a second period within second zone 34. First zone 32 extends from first end 10A towards second end 10B. Second zone 34 extends between first zone 32 and third zone 36, and third zone 36 extends between second zone 34 and second end 10B of wall 12. In some examples, first zone 32, second zone 34, and third zone 36 are contiguous as shown in FIG. 1. During operation, combustion within interior region 20 (i.e., combustion chamber) produces relatively higher heat flux within first zone 32 relative to second zone 34 due to proximity to fuel injectors and/or ignitors. Similarly, converging walls in third zone 36 increases heat flux within third zone 36 relative to second zone 34. That is to say, component 10 (i.e., combustor 30) is configured to have relatively higher heat flux within first zone 32 and third zone 36 relative to second zone 34.

[0017]While the present example describes a region of relatively low heat flux (i.e., second zone) relative to adjacent end regions (i.e., first zone 32 and third zone 36), other examples of component 10 can include any distribution of heat flux input into wall 12. Some examples of component 10 can have a decreasing and/or an increasing heat flux profile through interior surface of wall 12. In other examples, component 10 can include zones with increasing heat flux boarding zones of decreasing heat flux. In yet other examples, component 10 can have a heat flux profile defined by a polynomial function, an exponential function, or a logarithmic function, among other relationships.

[0018]FIG. 2 is a schematic view of an example undulating profile 38 of passage 14 associated with component 10 of FIG. 1. As shown, undulating profile 38 includes at least two undulations 40A and 40B and up to an arbitrary number of undulations 40A-40N in which “N” denotes an arbitrary number. First zone 32, second zone 34, and third zone 36 overlay undulating profile 38 as indicated. Undulating profile 38 includes first period P1, second period P2, and third period P3 that fall within first zone 32, second zone 34, and third zone 36, respectively. First period P1 and third period P3 are different than second period P2. In some examples, first period P1 also differs from third period P3. In each instance, the period of undulating profile varies based on heat flux distribution into component 10. The period of undulating profile is smaller within relatively high heat flux zones of component 10 while the period of undulating profile is larger within relatively lower heat flux zones of component 10. That is to say, regions of passage 14 in which the undulating profile has a relative smaller period relative to other regions of passage 14 have an undulating profile with higher undulation frequency relative to other regions of undulating profile, which have a profile with lower undulation frequency.

[0019]FIG. 3 is a partial developed cross-sectional view of component 10 taken along a surface through passages 14 depicted in as line B-B FIG. 1. As shown, passages are circumferentially spaced and include undulation profile 38. First period P1, second period P2, and third period P3 are shown and correspond to first zone 32, second zone 34, and third zone 36 as described in reference to FIG. 2. Cooling fluid enters at first end 10A of component, flowing through passages 14 to second end 10B as shown. Accordingly, component 10 includes increased cooling within first zone 32 and third zone 36 relative to second zone 34. Further, pressure drop due to cooling fluid flowing through passages 14 is less per unit length of passage extension within second zone 34 relative to first zone 32 and third zone 36.

Discussion of Possible Embodiments

[0020]The following are non-exclusive descriptions of possible embodiments of the present invention.

Component with Undulating Passages

[0021]A component according to an example embodiment of this disclosure, among other possible things, includes a wall and a passage. The wall bounds an interior region and extends along a component axis from a first end to a second end. The passage extends within the wall between the first end and the second end proximate to an interior surface of the wall. The passage includes an undulating profile comprising a plurality of undulations along an extension axis. The undulating profile includes a first period measured along the extension axis between a first pair of adjacent undulations that is different from a second period measured along the extension axis between a second pair of adjacent undulations.

[0022]The component of the preceding paragraph can optionally include, additionally and/or alternatively, any one or more of the following features, configurations and/or additional features.

[0023]A further embodiment of the foregoing component, wherein the first period can be less than the second period such that a first length between the first pair of adjacent undulations is less than a second length between the second pair of adjacent undulations.

[0024]A further embodiment of any of the foregoing components, wherein a first zone of the interior region can coincide with a first portion of the passage having the first period, the first zone coinciding with a higher heat flux relative to a lower heat flux within a second zone of the interior region coinciding with a second portion of the passage having the second period.

[0025]A further embodiment of any of the foregoing components, wherein the undulating profile of the passage can further include a third period measured along the extension axis between a third pair of adjacent undulations, and wherein the third period can be different than the second period.

[0026]A further embodiment of any of the foregoing components, wherein the third period can be different than the first period.

[0027]A further embodiment of any of the foregoing components, wherein the first period and the third period can be less than the second period such that a first length between the first pair of adjacent undulations and a third length between the third pair of adjacent undulations are less than a second length between the second pair of adjacent undulations.

[0028]A further embodiment of any of the foregoing components, wherein the second period can be intermediate of the first period and the third period.

Combustor Wall With Undulating Passages

[0029]A combustor according to an example embodiment of this disclosure, among other possible things, includes a wall and a passage. The wall bounds an interior region and extends along a component axis from a first end to a second end. The passage extends within the wall between the first end and the second end proximate to an interior surface of the wall. The passage includes an undulating profile comprising a plurality of undulations along an extension axis. The undulating profile includes a first period measured along the extension axis between a first pair of adjacent undulations that is different from a second period measured along the extension axis between a second pair of adjacent undulations.

[0030]The combustor of the preceding paragraph can optionally include, additionally and/or alternatively, any one or more of the following features, configurations and/or additional features.

[0031]A further embodiment of the foregoing combustor, wherein the first period can be less than the second period such that a first length between the first pair of adjacent undulations is less than a second length between the second pair of adjacent undulations.

[0032]A further embodiment of any of the foregoing combustors, wherein a first zone of the interior region can coincide with a first portion of the passage having the first period, the first zone coinciding with a higher heat flux relative to a lower heat flux within a second zone of the interior region coinciding with a second portion of the passage having the second period.

[0033]A further embodiment of any of the foregoing combustors, wherein the undulating profile of the passage can further include a third period measured along the extension axis between a third pair of adjacent undulations, and wherein the third period can be different than the second period.

[0034]A further embodiment of any of the foregoing combustors, wherein the third period can be different than the first period.

[0035]A further embodiment of any of the foregoing combustors, wherein the first period and the third period can be less than the second period such that a first length between the first pair of adjacent undulations and a third length between the third pair of adjacent undulations are less than a second length between the second pair of adjacent undulations.

[0036]A further embodiment of any of the foregoing combustors, wherein the second period can be intermediate of the first period and the third period.

[0037]A further embodiment of any of the foregoing combustors, wherein the undulating profile can have a continuously varying period from the first period to the second period.

[0038]A further embodiment of any of the foregoing combustors, wherein the wall can further include a first zone extending from the first end towards the second end.

[0039]A further embodiment of any of the foregoing combustors, wherein the first zone coincides with a first period of the undulating profile of the passage.

[0040]A further embodiment of any of the foregoing combustors, wherein the wall can further include a second zone extending between the first zone towards the second end.

[0041]A further embodiment of any of the foregoing combustors, wherein the first zone coincides with a first portion of interior region with higher heat flux during operation relative to a second portion of interior region coinciding with the second zone.

[0042]A further embodiment of any of the foregoing combustors, wherein the second zone can coincide with the second period of the undulating profile of the passage.

[0043]A further embodiment of any of the foregoing combustors, wherein the wall further can include a third zone extending between the second zone to the second end and coinciding with the third period of the undulating profile of the passage.

[0044]A further embodiment of any of the foregoing combustors, wherein the first zone, the second zone, and the third zone can coincide with a first heat flux, a second heat flux, and a third heat flux, respectively, that are mutually different.

[0045]A further embodiment of any of the foregoing combustors, wherein the third zone of the wall cam converge toward the axis.

[0046]A further embodiment of any of the foregoing combustors, wherein the first heat flux and the third heat flux are larger than the second heat flux.

[0047]A further embodiment of any of the foregoing combustors, wherein the first period and the third period can be less than the second period such that a first length between the first pair of adjacent undulations and a third length between the third pair of adjacent undulations are less than a second length between the second pair of adjacent undulations

[0048]A further embodiment of any of the foregoing combustors, wherein the undulating profile can have a continuously varying period from the first period to the second period and from the second period to the third period

A Method for Manufacturing a Component with Undulating Passages

[0049]A method according to an example embodiment of this disclosure, among other possible things, includes forming a passage extending through a wall of the component having an undulating profile. The undulating profile have at least a first period and a second period greater than the first period. The first period coincides with a first zone of the component configured to have higher heat flux than a second zone coinciding with the first period.

[0050]The method of the preceding paragraph can optionally include, additionally and/or alternatively, any one or more of the following features, configurations, additional components, and/or steps.

[0051]A further embodiment of the foregoing method can include forming the passage along an interior surface of the wall.

[0052]A further embodiment of any of the foregoing methods can include brazing an interior plate to the interior surface to enclose the passage.

[0053]While the invention has been described with reference to an exemplary embodiment(s), 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(s) disclosed, but that the invention will include all embodiments falling within the scope of the appended claims.