JP6290438B2 - Turbine engine - Google Patents

Description

CROSS REFERENCE TO PRIORITY AND CROSS REFERENCE TO RELATED APPLICATIONS This application claims priority to the following US patent applications, all of which were filed on February 25, 2014, the contents of each of which are hereby Incorporated herein:
"TURBINE ABRADABLE LAYER WITH ZIG-ZAG GROOVE PATTERN" assigned with application number 14 / 189,081
"TURBINE ABRADABLE LAYER WITH ASYMMETRIC RIDGES OR GROOVES" assigned with application number 14 / 189,035
"TURBINE ABRADABLE LAYER WITH PROGRESSIVE WEAR ZONE TERRACED RIDGES" assigned with application number 14 / 188,992.

  A co-filed international patent application entitled “TURBINE ABRADABLE LAYER WITH INCLINED SURFACE RIDGE OR GROOVE PATTERN” with case number 2015P01174WO and assigned an application number (unknown) is identified as a related application and is hereby incorporated by reference. Incorporated.

The following US patent applications were filed concurrently on February 25, 2014 and were identified as related applications for the purpose of reviewing the applications filed here, the entire contents of each application being hereby incorporated by reference: Incorporated in the description:
"TURBINE ABRADABLE LAYER WITH PROGRESSIVE WEAR ZONE MULTI DEPTH GROOVES" assigned with application number 14 / 188,813
"TURBINE ABRADABLE LAYER WITH PROGRESSIVE WEAR ZONE HAVING A FRANGIBLE OR PIXELATED NIB SURFACE" assigned with application number 14 / 188,941
"TURBINE ABRADABLE LAYER WITH PROGRESSIVE WEAR ZONE MULTI LEVEL RIDGE ARRAYS" assigned with application number 14 / 188,958
“TURBINE ABRADABLE LAYER WITH NESTED LOOP GROOVE PATTERN” assigned application number 14 / 189,011.

Background of the Invention The present invention relates to abradable surfaces for turbine engines having abradable surfaces, including gas or steam turbine engines, and to a method for reducing engine blade tip wear and blade tip leakage. In particular, various embodiments of the present invention are abradable surfaces having asymmetric front and rear ridge surface area densities that compensate for greater ridge erosion in the front zone and the blade tip in the rear zone during engine operation. To reduce wear, it relates to an abradable surface where the front ridge has a greater surface area density than the rear ridge.

2. Description of the Prior Art Known turbine engines, including gas turbine engines and steam turbine engines, have axially mounted turbine blades circumferentially surrounded by a turbine casing or housing. Hot gas flowing through the turbine blades causes blade rotation, which converts the thermal energy in the hot gas into mechanical work, which provides power to rotating machines such as generators. Is available to do. With reference to FIGS. 1-6, a known turbine engine, such as gas turbine engine 80, has a multi-stage compressor section 82, a combustor section 84, a multi-stage turbine section 86, and an exhaust system 88. Atmospheric pressure intake is drawn into the compressor section 82 generally in the direction of the flow arrow F along the axial length of the turbine engine 80. The intake air is progressively pressurized in the compressor section 82 by multiple rows of rotating compressor blades, directed to the combustor section 84 by the corresponding compressor vanes, mixed with fuel in the combustor section 84, and ignited. Is done. The ignited fuel / air mixture is now directed to successive rows R ₁ , R _2, etc. in the turbine section 86 at a higher pressure and speed than the original intake air. The engine rotor and shaft 90 has a plurality of rows of blade profile turbine blades 92 ending at a distal blade tip 94 in the compressor 82 and turbine 86 sections. For convenience and simplicity, further description of the turbine blades and abradable layers in the engine will focus on the embodiment and application of the turbine section 86, although similar configurations are applicable to the compressor section 82. Each blade 92 has a concave high pressure side 96 and a convex low pressure side 98. The high-speed and high-pressure combustion gas flowing in the combustion flow direction F imparts rotational motion to the blade 92 to rotate the rotor. As is well known, some of the mechanical power imparted to the rotor shaft is available to do useful work. Combustion gas is constrained by the turbine casing 100 radially distal to the rotor and by an air seal 102 proximal to the rotor. Referring to the first row section shown in FIG. 2, each upstream vane 104 and downstream vane 106 directs upstream combustion gases substantially parallel to the angle of incidence of the leading edge of the turbine blade 92 so that the rear of the blade Divert downstream combustion gas from the edge.

  The turbine casing 100 of the turbine engine 80 near the blade tip 94 is covered by a plurality of fan-shaped abradable components 100, each abradable component 100 being held in and coupled to the casing. And an abradable substrate 120 that is in a spaced-apart relationship facing the blade tip by a blade tip gap G. Abradable substrates are often constructed of metal / ceramic materials that have high thermal and thermal corrosion resistance and maintain structural integrity at high combustion temperatures. Since the metal ceramic material of the abradable surface 120 is often more susceptible to scraping than the material of the turbine blade tip 94, the blade tip gap G may cause blade tip wear at best or too early, or worse, The situation is maintained to avoid contact between two opposing components that may cause engine damage. Some known abradable components 110 are constructed with a monolithic metal / ceramic abradable substrate 120. Other known abradable components 110 include a plurality of closely packed hollow ceramic spherical particles surrounded by smaller particle ceramic filler, as described in US Pat. No. 6,641,907. The layer is constructed with a composite matrix composite (CMC) structure having a ceramic support surface 112 to which a fracturing graded thermal insulation (FGI) ceramic layer is bonded. Spherical particles having different properties are layered on the substrate 120, and the spheres that are generally more easily scraped form an upper layer to reduce wear on the blade tip 94. Another CMC structure is described in US 2008/0274336, where the surface has a cut grooved pattern between hollow ceramic spheres. The grooves are intended to reduce the cross-sectional area of the abradable surface material so as to reduce potential blade tip 94 wear even if the blade tip 94 contacts the abradable surface. Another commonly known abradable component 110 is configured with a metal base layer support surface 112 provided with a sprayed ceramic / metal layer that forms an abradable substrate layer 120. As described in more detail, the sprayed metal layer may have grooves, recesses or ridges so as to reduce the cross-section of the abradable face material to reduce potential blade tip 94 wear. Good.

  In addition to the desire to prevent premature wear of the blade tips 94 or contact with the abradable surface 120, as shown in FIG. 3, for ideal air flow and power efficiency, each blade tip 94 is Desirably, a uniform blade for the abradable component 110 as small as possible to minimize axial blade tip air leakage L between the high pressure blade side 96 and the low pressure blade side 98 and in the combustion flow direction F. It has a tip gap G (ideally a zero gap). However, manufacturing and operating tradeoffs require a blade tip gap G that is greater than zero. Such trade-offs include a stack of tolerances of interacting components, which allows for a blade configured at the higher end with an acceptable radial length tolerance and an acceptable radial tolerance. The abradable surface 120 of the abradable component configured at the lower end does not excessively collide with each other during operation. Similarly, small mechanical alignment variations during engine assembly can cause local variations in blade tip clearance. For example, in a multi-meter axial length turbine engine having an inner diameter of many meters of turbine casing abradable substrate 120, very small mechanical alignment variations cause local blade tip gap G variations of a few millimeters. there is a possibility.

During operation of the turbine engine 80, the turbine engine casing 100 may experience non-circular (eg, egg-shaped) thermal distortion, as shown in FIGS. As the engine is burned to generate power and then cooled for maintenance after thousands of hours of power generation, the thermal distortion potential of casing 100 increases during the operating cycle of turbine engine 80. . In general, as shown in FIG. 6, the distortion of the larger casing 100 and abradable component 110 causes the lateral positions of the right 124 and left 128 in the lateral direction (ie, 3:00 and 9:00). Compared to the uppermost 122 and lowermost 126 casing circumferential positions (ie, 6:00 and 12:00 positions). For example, as shown in FIG. 4, if casing distortion at 6:00 position causes blade tip contact with the abradable substrate 120, one or more of the blade tips will be worn during operation. The blade tip clearance may be locally increased in various other less deformed circumferential portions of the turbine casing 100 from an ideal clearance G to a larger clearance G as shown in FIG. Increase to _W. Distortion of excessive blade gap G _W increases the blade tip leakage L, and hot combustion gases, deflecting away from the blades of the turbine blades 92, reduces the efficiency of the turbine engine.

  In the past, a flat abradable surface substrate 120 was utilized, and the specification of the blade tip gap G was traditionally selected to provide at least a minimum overall gap, thereby providing turbine components. Contact between blade tip 94 and abradable surface substrate is prevented over a wide range of manufacturing tolerance stacks, assembly alignment variations and thermal distortion. Thereby, a relatively wide traditional gap G specification is selected to avoid engine efficiency sacrificed by tip / substrate contact. The commercial desire to increase engine efficiency for fuel conservation has driven the specification of a smaller blade tip gap G. The specification of the blade tip gap G is preferably 2 mm or less, preferably close to 1 mm.

In order to reduce the possibility of blade tip / substrate contact, an abradable component having a metal base layer support with a sprayed metal / ceramic abradable surface is a tertiary as shown in FIGS. It is configured with the original planar figure outline. A typical known abradable surface component 130 of FIGS. 7 and 10 has a metal base layer support 131 for connection to the turbine casing 100, and the metal base layer support 131 is sprayed. Metal / ceramic layers are deposited and formed into three-dimensional ridge and groove profiles by known deposition or removal material processing methods. In particular, in these cited drawings, each of the plurality of ridges 132 has a common height H _R distal ridge tip surface 134, which includes a blade tip 94, A blade tip gap G is defined between the distal ridge tip surface 134. Each ridge also has side walls 135 and 136. Side walls 135 and 136 extend from the substrate surface 137 and define a groove 138 between the opposing side walls of successive ridges. Ridge 132 is arranged with a parallel spacing S _R between the center line of successive ridges defines a groove width W _G. The surface symmetry of the abradable component, the groove depth D _G corresponds to the ridge height H _R. Compared to a solid smooth surface abradable, the ridge 132 has a smaller cross-section and when the blade tip gap G becomes so small that the blade tip 94 contacts the one or more tips 134, Has a more limited scraping contact. However, the relatively high, widely spaced ridges 132 allow blade leakage L into the grooves 138 between the ridges as compared to conventional continuous flat abradable surfaces. In an effort to reduce blade tip leakage L, ridge 132 and groove 138 are either horizontally in the direction of combustion flow F (not shown) or across the width of abradable surface 137 as shown in FIG. Are directed diagonally, which tends to prevent leakage. Another known abradable component 140 shown in FIG. 8 has a rhombic ridge plan view 142 with a flat, equal height ridge tip 144 with grooves 148 arranged in a cruciform pattern. It is defined. An additional known abradable component uses a triangular rounded or flat tip triangular ridge 152 as shown in FIGS. In the abradable component 150 of FIGS. 9 and 11, each ridge 152 has symmetrical side walls 155, 156 that terminate at a flat ridge tip 154. All ridge tips 154 have a common height H _R and protrude from the substrate surface 157. The groove 158 is curved and has the same planar graphic contour as the warp line of the blade tip 94. The curved groove 158 is more difficult to form than the linear groove 138 or 148 of the abradable component as shown in FIGS.

  Past abradable component designs have required a significant compromise between blade tip wear caused by contact between the blade tip and the abradable surface and blade tip leakage which reduces turbine engine operating efficiency. Optimized engine operating efficiency prevents air leakage through the blade tip gap and reduces the blade tip clearance and smooth consistent flat abradable surface to increase initial engine performance and energy conservation Needed topology. In another motivation for increased gas turbine operating efficiency and flexibility, a so-called “rapid start” mode engine was constructed that required a more rapid full power increase (on the order of 40-50 Mw / min). Abrupt growth rates are caused by more rapid thermal and mechanical growth and greater distortion and greater mismatch in growth rates between rotating and stationary components and blades into the abradable coating of the ring segment Aggravated the potential larger inrush of the tip. This, in turn, is more common in “quick start” mode engines to avoid premature blade tip wear than is required for engines configured only for “standard” start cycles. A large turbine tip clearance was required. Therefore, a design choice was required to balance faster blade start / larger blade tip clearance with lower operating efficiency or standard starter / smaller blade tip clearance with greater operating efficiency. Traditionally, standard or quick start engines have required different configurations to provide different required blade tip clearance parameters for both designs. Regardless of the standard or quick start method, reducing the blade tip clearance for engine efficiency optimization will ultimately result in the risk of blade tip wear prematurely, widening the blade tip clearance, and finally Reduces long-term engine performance efficiency during the engine operating cycle. The ceramic matrix composite (CMC) abradable component design described above has the advantage of air flow control and flatness by using a more flexible upper abradable layer to reduce blade tip wear. An attempt was made to maintain a small blade tip clearance on the surface contour abradable surface. The abradable component of US 2008/0274336 also sought to reduce blade tip wear by incorporating grooves between the upper layer hollow ceramic spheres. However, the groove dimensions were originally limited by the stuffing interval and diameter of the spheres to prevent sphere destruction. Add a uniform height abradable surface ridge to the sprayed substrate profile as a compromise solution to reduce blade tip clearance while reducing potential scraping contact surface area between ridge tip and blade tip This reduced the possibility of premature blade tip wear / increased blade tip clearance, but at the expense of increased blade tip leakage into the grooves between the ridges. As noted above, attempts have been made to reduce blade tip leakage by changing the orientation of the ridge array in the plan view to attempt to block or control leakage air flow into the groove.

SUMMARY OF THE INVENTION The objectives of the various embodiments of the present invention are to provide blade tolerance / stack progression, assembly alignment variability, blade / progress during one or more engine operating cycles in a manner that does not cause excessive blade tip wear. Increasing engine efficiency performance by reducing and controlling the blade tip clearance despite local variations caused by factors such as casing deformation.

  In localized wear zones where the abradable surface and the blade tip are in contact with each other, the purpose of the various embodiments of the present invention is to maintain minimal blade tip leakage in these zones and to ensure that these localized wear. The blade tip wear is reduced to a minimum while maintaining a relatively narrow blade tip gap outside the zone.

  The purpose of other embodiments of the invention is to increase turbine operating efficiency without excessive risk of premature blade tip wear that can result from a potentially increased number of local blade tip / abradable surface contact zones. That is.

  Still another object of the invention is to prevent and / or direct blade tip leakage while providing a larger abradable ridge surface area in the forward zone to compensate for abradable surface erosion during engine operation. To reduce blade tip leakage by utilizing a composite, separate front and back profile and planographic arrangement of abradable ridges and grooves to be converted.

  The purpose of the additional embodiments is to scrape material and other particulate matter axially through the turbine along the abradable surface so as not to affect the rotating turbine blade or to cut the turbine blade. It is to provide a groove channel for conveying.

  In various embodiments of the present invention, a turbine casing abradable component reduces, redirects and / or blocks blade tip airflow leakage downstream from the turbine blade blade high pressure side to the low pressure side rather than from the low pressure side. For this purpose, it has a clear front upstream and rear downstream composite multi-directional groove and a vertically extending ridge planographic pattern. The planographic pattern embodiment is a composite multi-groove / ridge pattern with a clear front upstream (zone A) and rear downstream pattern (zone B). These combined Zone A and Zone B ridge / groove array plan views directly impede gas flow leakage from the pressure side of the turbine blade blade to the blade suction side in the local blade leakage direction L. In addition, the gas flow trapped in the groove is directed in the direction of the downstream combustion flow F. The forward zone is generally defined between the leading edge and the middle of the blade blade chord at a cutoff point where a line parallel to the axis of the turbine 80 is approximately tangential to the pressure side surface of the blade. Approximately one third to one half of the axial length of the blade. The rest of the array pattern includes the rear zone B. The grooves and ridges in the rear downstream zone B are oriented at an angle in the direction opposite to the blade rotation direction R. The range of angles is about 30% to 120% of the warp or trailing edge angle of the associated turbine blade 92. In some embodiments, the plan view of the ridge / groove arrangement in the upstream or forward zone A is designed to compensate for the larger abradable erosion that occurs during engine operation, in order to compensate for the ridge / groove plane in the downstream or structural zone B. It has a larger abradable surface area than the graphic.

  In various other embodiments, the abradable component is configured with a vertically projecting ridge or rib having a first lower wear zone and a second upper wear zone. The first lower zone of the ridge near the abradable surface is a planar graphic arrangement and protrusion adjusted to reduce, redirect and / or block blade tip airflow leakage into the groove between the ridges The part is configured to optimize engine air flow characteristics. The lower zone of the ridge is also optimized to increase the mechanical and thermal structural integrity, thermal resistance, thermal corrosion resistance and wear life of the abradable components and surfaces. The ridge upper zone is formed above the lower zone and is optimized to minimize blade tip clearance and wear by making it easier to scrape than the lower zone. Various embodiments of the abradable component provide easier scraping of the upper zone with an upper support or tip having a smaller cross-sectional area than the lower zone rib structure. In some embodiments, the upper subridge or tip is configured to bend or otherwise flex upon small blade tip contact and / or to wear and / or shear upon larger blade tip contact. Has been. In other embodiments, the upper zone support or tip is worn only at those tips that are in local contact with one or more blade tips, while others outside the local wear zone remain intact. As such, it is pixelated into an array of upper wear zones. Although the upper zone portion of the ridge is worn, the upper zone portion is less prone to blade tip wear than conventionally known monolithic ridges. In some embodiments of the present invention, when the upper zone ridge portion is worn, the remaining lower ridge portion maintains engine efficiency by controlling blade tip leakage. When the local blade tip clearance is further reduced, the blade tip wears the lower ridge portion at that location. However, the relatively high ridge outside the local wear area of its lower ridge portion maintains a smaller blade tip clearance to maintain engine performance efficiency. Additionally, the multi-level wear zone profile allows one turbine engine design to be operated in standard or “rapid start” mode. When operated in the rapid start mode, the engine has a tendency to wear the upper wear zone layer with less potential for excessive blade tip wear while preserving the lower wear zone aerodynamic function. If the same engine is operated in standard start mode, there is a higher possibility that both the abradable upper and lower wear zones will be preserved for efficient engine operation. Three or more layers of wear zones (eg, upper, middle and lower wear zones) can be used in abradable components constructed in accordance with embodiments of the present invention.

  In some invention embodiments, the ridge and groove profile and the abradable surface area of the planographic array are multi-layered with selective orientation angles and / or cross-sectional profiles selected to reduce blade tip leakage. It is adjusted locally or globally over the abradable component, such as by forming a groove. In some embodiments, the abradable component surface plan graphic arrangement and ridge and groove contours provide improved blade tip leakage airflow control, but simpler manufacturing techniques than known abradable components Also promote.

  Some of these and other proposed issues are, in one or more embodiments of the invention, a turbine abradable component that is oriented against a rotating turbine blade tip circumferential movement trajectory. This is achieved by a turbine abradable component characterized by a turbine engine ring segment abradable component adapted to be coupled to the inner periphery of the turbine casing. The corresponding blade tip has a direction of rotation, a leading edge, a chord mid cut-off point on the pressure side concave surface that is substantially parallel to the surface tangent to the corresponding turbine blade rotation axis, and a trailing edge. The component has a support surface adapted to be coupled to the inner periphery of the turbine casing surrounding the turbine blade axis of rotation. The support surface has upstream and downstream ends and a support surface axis adapted to be oriented parallel to the corresponding turbine blade rotation axis. An abradable substrate is a substrate having a composite angular planar graphic pattern of grooves and vertically protruding ridges coupled to a support surface and defined by a pair of front and rear linear segment portions joined by a transition portion Having a surface. Each forward linear segment portion begins near the support surface upstream end and is oriented within a range or angle of ± 10 degrees relative to the support surface axis. In some embodiments, the forward linear segment portion is substantially parallel to the support surface axis. The forward linear segment portion terminates between the end of the support surface upstream of the intended turbine blade chord mid cut-off point, in the radial and axial projected positions of the moving trajectory. Each rear linear segment portion is oriented angularly opposite the corresponding turbine blade rotation direction, beginning downstream of the turbine blade chord mid cut-off point and ending near the downstream end of the support surface. The front ridge in the front linear segment portion has a greater surface area density than the rear ridge in the rear linear segment portion. In some embodiments, the front ridge is wider than the rear ridge to form an abradable surface having a greater front end density. In some embodiments of the present invention, the transition section ridge and groove define a curved plan view. In other embodiments, the ridge has a distal protruding tip that is inclined with respect to the support surface.

  Another embodiment of the present invention is a rotor comprising a turbine housing and a blade rotatably mounted on the turbine housing, the distal tip of the blade being a blade tip in the direction of blade rotation and axially relative to the turbine housing. The present invention relates to a turbine engine characterized by a rotor that forms a circumferential movement track. The blade tip has a leading edge, a chord mid cut-off point on the pressure side concave surface whose surface tangent is substantially parallel to the corresponding turbine blade rotation axis, and a trailing edge. Embodiments of the invention feature an abradable component having a support surface adapted to be coupled to an inner periphery of a turbine housing surrounding a turbine blade axis of rotation. The support surface has upstream and downstream ends and a support surface axis adapted to be oriented parallel to the turbine blade rotation axis. In these embodiments, the abradable substrate is coupled to the support surface and is defined by a composite angle of grooves and vertically protruding ridges defined by a pair of front and rear linear segment portions joined by a transition portion. It has a substrate surface with a planar graphic pattern. Each forward linear segment portion begins near the upstream end of the support surface and is oriented within a range or angle of ± 10 degrees with respect to the support surface axis and is moving trajectory of the intended turbine blade chord mid cut-off point Between the radial and axial projected positions upstream of the support surface end. Each rear linear segment portion begins downstream of the intended turbine blade chord mid cut-off point, is oriented angularly opposite to the corresponding turbine blade rotation direction, and ends near the downstream end of the support surface . The front ridge in the front linear segment portion has a greater surface area density than the rear ridge in the rear linear segment portion.

  Each object and feature of the invention can be applied jointly or in multiple combinations by any person skilled in the art in any combination or subcombination.

  The teachings of the present invention can be readily understood by considering the following detailed description in conjunction with the accompanying drawings, in which:

1 is a partial axial cross-sectional view of a typical known gas turbine engine. FIG. FIG. 2 is a detailed cross-sectional elevation view of a first row turbine blade and vane showing a blade tip gap G between the blade tip of the turbine engine of FIG. 1 and an abradable component. 1 is a radial cross-sectional schematic of a known turbine engine having an ideal uniform blade tip gap G between all blades and all circumferential orientations about the engine abradable surface. Radial section of a known non-circular turbine engine showing contact between the blade tip and the abradable surface at the uppermost circumferential position at 12:00 and the lowermost circumferential position at 6:00 FIG. It is a radial sectional schematic view of the original design specifications blade tip clearance known turbine engine is actuated while having a large excess blade tip clearance G _W than G. 1 is a schematic radial cross-sectional view of a known turbine engine highlighting a circumferential zone where blade tip wear is more likely to occur and a zone where blade tip wear is less likely to occur. 1 is a plan view of a known ridge and groove pattern for a turbine engine abradable surface. FIG. 1 is a plan view of a known ridge and groove pattern for a turbine engine abradable surface. FIG. 1 is a plan view of a known ridge and groove pattern for a turbine engine abradable surface. FIG. FIG. 10 is a cross-sectional elevation view of a known ridge and groove pattern for a turbine engine abradable surface viewed along the respective cross-section CC of FIGS. 7 and 9. FIG. 10 is a cross-sectional elevation view of a known ridge and groove pattern for a turbine engine abradable surface viewed along the respective cross-section CC of FIGS. 7 and 9. 2 is a plan view of a “hockey stick” shaped ridge and groove pattern of a turbine engine abradable surface, according to an exemplary embodiment of the present invention, shown with a schematic overlap of turbine blades. FIG. 2 is a plan view of a “hockey stick” shaped ridge and groove pattern of a turbine engine abradable surface, according to an exemplary embodiment of the present invention, shown with a schematic overlap of turbine blades. FIG. 2 is a plan view of a “hockey stick” shaped ridge and groove pattern of a turbine engine abradable surface, according to an exemplary embodiment of the present invention, shown with a schematic overlap of turbine blades. FIG. 2 is a plan view of a “hockey stick” shaped ridge and groove pattern of a turbine engine abradable surface, according to an exemplary embodiment of the present invention, shown with a schematic overlap of turbine blades. FIG. 2 is a plan view of a “hockey stick” shaped ridge and groove pattern of a turbine engine abradable surface, according to an exemplary embodiment of the present invention, shown with a schematic overlap of turbine blades. FIG. 2 is a plan view of a “hockey stick” shaped ridge and groove pattern of a turbine engine abradable surface, according to an exemplary embodiment of the present invention, shown with a schematic overlap of turbine blades. FIG. Another “hockey stick” -like ridge for a turbine engine abradable surface having a vertically oriented ridge or rib array consistent with the direction of turbine blade rotation, according to another exemplary embodiment of the present invention; 2 is a plan view of a groove and a schematic overlap of turbine blades. FIG. Another “hockey stick” -like ridge for a turbine engine abradable surface having a vertically oriented ridge or rib array consistent with the direction of turbine blade rotation, according to another exemplary embodiment of the present invention; 2 is a plan view of a groove and a schematic overlap of turbine blades. FIG. A typical continuous groove hockey stick abradable surface profile of each of the types shown in FIGS. 12-17 and an interrupting vertical ridge hockey stick abradable surface profile of the type shown in FIGS. FIG. 6 is a comparative graph of simulated blade tip leakage mass flux from the leading edge to the trailing edge for a split groove with. Plane of another “hockey stick” -like ridge and groove putter for abradable surfaces with intersecting ridges and grooves and a general overlap of turbine blades according to another exemplary embodiment of the present invention FIG. Similar to FIGS. 18 and 19, having vertically oriented ridges offset laterally across the abradable surface in the axial direction of the turbine engine, according to another exemplary embodiment of the present invention. FIG. 6 is a plan view of another “hockey stick” shaped ridge and groove pattern for an abradable surface. In accordance with another exemplary embodiment of the present invention, a “zigzag” ridge for an abradable surface having a ridge and groove arrangement oriented horizontally across the abradable surface in the axial direction of the turbine engine It is a top view of a groove pattern. FIG. 5 is a plan view of a “zigzag” ridge and groove pattern for an abradable surface having a ridge and groove array oriented diagonally across the abradable surface, according to another exemplary embodiment of the present invention. It is. FIG. 6 is a plan view of a “zigzag” ridge and groove pattern for an abradable surface having a V-shaped ridge and groove array across the abradable surface, in accordance with another exemplary embodiment of the present invention. 2 is a plan view of an overlaid looped ridge and groove pattern of a turbine engine abradable surface, according to an exemplary embodiment of the present invention, shown with a schematic overlap of turbine blades. FIG. 2 is a plan view of an overlaid looped ridge and groove pattern of a turbine engine abradable surface, according to an exemplary embodiment of the present invention, shown with a schematic overlap of turbine blades. FIG. 2 is a plan view of an overlaid looped ridge and groove pattern of a turbine engine abradable surface, according to an exemplary embodiment of the present invention, shown with a schematic overlap of turbine blades. FIG. 2 is a plan view of an overlaid looped ridge and groove pattern of a turbine engine abradable surface, according to an exemplary embodiment of the present invention, shown with a schematic overlap of turbine blades. FIG. 1 is a plan view of a maze or spiral ridge and groove pattern of a turbine engine abradable surface according to an exemplary embodiment of the present invention, shown with a schematic overlap of turbine blades. FIG. 1 is a plan view of a maze or spiral ridge and groove pattern of a turbine engine abradable surface according to an exemplary embodiment of the present invention, shown with a schematic overlap of turbine blades. FIG. 1 is a plan view of a maze or spiral ridge and groove pattern of a turbine engine abradable surface according to an exemplary embodiment of the present invention, shown with a schematic overlap of turbine blades. FIG. 1 is a plan view of a maze or spiral ridge and groove pattern of a turbine engine abradable surface according to an exemplary embodiment of the present invention, shown with a schematic overlap of turbine blades. FIG. In another exemplary embodiment of the present invention, in a plan view of a composite angle with curved rib transition section configuration ridges and groove patterns for a turbine engine abradable surface and a general overlap of turbine blades is there. In another exemplary embodiment of the present invention, in a plan view of a composite angle with curved rib transition section configuration ridges and groove patterns for a turbine engine abradable surface and a general overlap of turbine blades is there. 34 and 35 of the present invention, each of the typical compound angles with curved rib transition section configuration ridges and groove pattern abradable surfaces, typical known pairs of the type shown in FIG. In a comparative graph of simulated blade tip leakage mass flux from leading edge to trailing edge for abradable surface contours of square ridge and groove patterns and known axially aligned ridge and groove patterns abradable surfaces is there. FIG. 6 is a plan view of a multi-height ridge profile configuration for abradable surfaces and a corresponding groove pattern suitable for use in a standard or “rapid start” engine mode, according to an exemplary embodiment of the present invention. . FIG. 38 is a cross-sectional view of the abradable surface embodiment of FIG. 37 viewed along CC in FIG. 37. FIG. 39 is a schematic elevational cross-sectional view of the moving blade tip and abradable surface embodiment of FIGS. 37 and 38 illustrating blade tip leakage L and blade tip boundary layer flow according to an embodiment of the present invention. FIG. 40 is a schematic elevational sectional view similar to FIG. 39 showing multiple height dimensions of blade tip gap G, grooves and ridges according to an embodiment of the present invention. FIG. 40 is a schematic elevational sectional view similar to FIG. 39 showing multiple height dimensions of blade tip gap G, grooves and ridges according to an embodiment of the present invention. FIG. 12 is an elevational sectional view of a known abradable surface ridge and groove profile similar to FIG. 11. FIG. 5 is an elevational cross-sectional view of a multi-height stepped profile ridge configuration for an abradable surface and a corresponding groove pattern according to an embodiment of the present invention. FIG. 5 is an elevational cross-sectional view of another embodiment of a multi-height stepped profile ridge configuration for an abradable surface and a corresponding groove pattern. FIG. 5 is an elevational cross-sectional view of a multi-depth groove profile configuration and corresponding ridge pattern for an abradable surface, according to an embodiment of the present invention. FIG. 6 is an elevational cross-sectional view of an asymmetric contour ridge configuration for an abradable surface and a corresponding groove pattern, according to an embodiment of the present invention. FIG. 6 is a perspective view of an asymmetric contour ridge configuration and a multi-depth parallel groove contour pattern for an abradable surface, according to an embodiment of the present invention. FIG. 4 is a perspective view of an asymmetric contour ridge configuration for abradable surfaces and a multi-depth intersecting groove contour pattern, according to an embodiment of the present invention, with the upper groove tip longitudinally relative to the ridge tip. . FIG. 6 is a perspective view of another embodiment of the present invention of an asymmetric profile ridge configuration and a multi-depth intersecting groove profile pattern for an abradable surface, the upper groove being perpendicular to the ridge tip and longitudinally; It is inclined to. FIG. 5 is an elevational cross-sectional view of a cross-section of a multi-depth parallel groove profile configuration in a symmetrical profile ridge for an abradable surface, according to another embodiment of the present invention. FIG. 6 is an elevational cross-sectional view of each of the multiple depth parallel groove profile configurations in a symmetric profile ridge for an abradable surface, according to one embodiment of the present invention, with the upper groove transverse to the ridge tip. It is tilted. FIG. 6 is an elevational cross-sectional view of each of the multiple depth parallel groove profile configurations in a symmetric profile ridge for an abradable surface, according to one embodiment of the present invention, with the upper groove transverse to the ridge tip. It is tilted. FIG. 6 is a perspective view of an abradable surface according to an embodiment of the present invention having an asymmetric non-parallel wall ridge and multiple depth grooves. FIG. 5 is an elevational cross-sectional view of each of the multiple depth parallel groove profile configurations in a trapezoidal profile ridge for an abradable surface, with the upper groove perpendicular to the ridge tip, according to an alternative embodiment of the present invention. Is or is tilted laterally. FIG. 5 is an elevational cross-sectional view of each of the multiple depth parallel groove profile configurations in a trapezoidal profile ridge for an abradable surface, with the upper groove perpendicular to the ridge tip, according to an alternative embodiment of the present invention. Is or is tilted laterally. FIG. 5 is an elevational cross-sectional view of each of the multiple depth parallel groove profile configurations in a trapezoidal profile ridge for an abradable surface, with the upper groove perpendicular to the ridge tip, according to an alternative embodiment of the present invention. Is or is tilted laterally. FIG. 6 is a plan view of a multi-level cross groove pattern for an abradable surface according to an embodiment of the present invention. FIG. 4 is a perspective view of a stepped profile abradable surface ridge according to one embodiment of the present invention, wherein the upper level ridge has pixel-raised rib tips protruding from the lower ridge flat. FIG. 59 is an elevational view of a row of raised pixelated tips protruding from the lower ridge flat, taken along CC in FIG. 58. 59 is an alternate embodiment of the raised tip of FIG. 59 according to one embodiment of the present invention, wherein the proximal tip portion of the tip tip is made of a material having different physical properties than the material below the layer. It is composed of layers. FIG. 59 is a schematic plan view of the pixelated upper tip embodiment of FIG. 58, with the turbine blade tip deflecting the tip during blade rotation. FIG. 59 is a schematic elevational view of the pixel-like upper tip embodiment of FIG. 58, wherein the turbine blade tip shears all or part of the raised tip during blade rotation, causing the lower ridge and its flats to It is left as it is and is spaced radially from the blade tip by a blade tip gap. FIG. 59 is a schematic elevation view of the pixel-like upper tip embodiment of FIG. 58, wherein the turbine blade tip shears all of the raised tips and wears the flat surface of the lower ridge portion during blade rotation. ing. For a turbine engine abradable, similar to the embodiment of FIGS. 34 and 35, with a constant ridge / groove spacing or pitch and varied ridge width, according to another exemplary embodiment of the present invention. FIG. 9 is a composite angle plan view or plan view with curved rib transition section configuration ridges and groove patterns. A trapezoid for an abradable surface, similar to that of FIGS. 54-56, without an upper groove perpendicular or transversely inclined to the ridge tip, according to an alternative embodiment of the invention It is front sectional drawing of the parallel groove | channel outline structure in an outline ridge. FIG. 6 is a front cross-sectional view of an asymmetric profile ridge configuration and corresponding groove pattern with sloped ridge tip faces for abradable surfaces (some with sloped groove base faces), according to embodiments of the present invention. . FIG. 6 is a front cross-sectional view of an asymmetric profile ridge configuration and corresponding groove pattern with sloped ridge tip faces for abradable surfaces (some with sloped groove base faces), according to embodiments of the present invention. . FIG. 6 is a front cross-sectional view of an asymmetric profile ridge configuration and corresponding groove pattern with sloped ridge tip faces for abradable surfaces (some with sloped groove base faces), according to embodiments of the present invention. . FIG. 6 is a front cross-sectional view of an asymmetric profile ridge configuration and corresponding groove pattern with sloped ridge tip faces for abradable surfaces (some with sloped groove base faces), according to embodiments of the present invention. . Inclined in the direction opposite to the blade rotation direction for the abradable surface, suitable for specifications in standard or “rapid start” engine mode for the abradable surface according to embodiments of the present invention (some Is also a front cross-sectional view of an asymmetric contour ridge configuration with multiple height inverted angle sidewalls. Inclined in the direction opposite to the blade rotation direction for the abradable surface, suitable for specifications in standard or “rapid start” engine mode for the abradable surface according to embodiments of the present invention (some Is also a front cross-sectional view of an asymmetric contour ridge configuration with multiple height inverted angle sidewalls.

To facilitate understanding, identical reference numerals have been used, where possible, to indicate identical elements that are common to multiple figures. The drawings are not to scale. The following common symbols for dimensions, cross section, fluid flow, turbine blade rotation, axial or radial orientation, and fluid pressure are used throughout the various inventive embodiments described herein. Yes.
A A front or upstream zone of the abradable surface B Bone or rear zone of the abradable surface CC Absorbable cross section DG _G abradable groove depth F Flow direction through the turbine engine G Turbine blade tip and abradable Gw Gap G _W Gap Gap between worn turbine blade tip and abradable surface H _R Abradable ridge height L Turbine blade tip leakage P Plan view or plan view of abradable surface P _P turbine also referred to as second column S _R pitch of the blades more first row R ₂ turbine engine turbine section of lower pressure side or suction side R turbine blade rotation direction R ₁ turbine engine turbine section of the high pressure side P _S turbine blades, a width W _R ablation interval W _G abradable groove of abradable ridge centerline Double ridge width α Plane angle of abradable groove relative to the axial dimension of the turbine engine β Angle of abradable ridge side wall relative to vertical or vertical abradable surface γ Abradable groove relative to abradable ridge height Forward / backward tilt angle Δ Skew angle of abradable groove with respect to longitudinal axis of abradable ridge ε Skew angle of abradable groove with respect to abradable surface and / or ridge surface Φ Arc angle of abradable groove

DETAILED DESCRIPTION The exemplary embodiments of the present invention described herein can be readily utilized in abradable components for turbine engines, including gas turbine engines. In various embodiments, the turbine casing abradable component is used to reduce, redirect and / or block blade tip airflow leakage downstream from the turbine blade blade high pressure side to the low pressure side rather than from the low pressure side. It has a clear front upstream and rear downstream composite multi-directional groove and a vertically projecting ridge platform pattern. The planographic pattern embodiment is a composite multi-groove / ridge pattern with a clear front upstream (zone A) and rear downstream pattern (zone B). These combined Zone A and Zone B Ridge / Groove array plan views directly impede gas flow leakage from the turbine blade pressure side to the blade suction side in the local blade leakage direction L. The gas flow trapped in the groove is directed in the direction of the downstream combustion flow F. The forward zone is generally defined between the leading edge and the middle of the blade blade chord at a cutoff point where a line parallel to the turbine axis is approximately tangential to the pressure side surface of the blade. , Approximately one third to one half of the overall axial length of the blade. The rest of the array pattern includes the rear zone B. In some embodiments, the grooves and ridges in the front upstream zone A are oriented at an angle range of ± 10 degrees relative to the support surface axis or blade rotation axis in the engine. In particular, some embodiments orient the forward zone A grooves and ridges parallel to the support surface / blade rotation axis. The grooves and ridges in the rear downstream zone B are oriented at an angle in the direction opposite to the blade rotation direction R. The range of angles is about 30% to 120% of the warp or trailing edge angle of the associated turbine blade 92. In some embodiments, for applications where there is a greater possibility of abradable erosion during engine operation, but there is a lower possibility of blade tip penetration in the forward zone, the forward zone A The ridges have a higher surface area density and smaller shaving than the ridges in the rear zone. Conversely, in the rear zone B, coating erosion is less of a problem, but in applications where there is a greater possibility of blade / abradable coating contact during engine operation, the ridge is lower than the density in the front zone. It is more desirable to have a surface area density and higher ease of shaving. The configuration in which the density of the abradable surface varies has sufficient abradable material to maintain the desired blade tip clearance in forward zone A, and the abradable in that zone during ongoing engine operation. A compromise is provided by reducing the surface density in the rear zone B to compensate for surface erosion and further reduce the possibility of turbine blade tip wear. In some applications, it is desirable to change the machinability characteristics of the component abradable material in the front and rear zones, alone or in combination with changing the ridge / rib surface area density.

  In various embodiments of the present invention, a thermally sprayed or additionally formed ceramic / metal abradable layer of an abradable component comprises a first lower wear zone and a second upper wear zone. It is comprised including the ridge or rib which protrudes in the perpendicular direction which has. The first lower zone of the ridge near the sprayed abradable surface is a plan view adjusted to reduce, redirect and / or block blade tip airflow leakage into the groove between the ridges The arrangement and protrusions are configured to optimize engine airflow characteristics. In some embodiments, the upper wear zone of the sprayed abradable layer is about two thirds to one third of the height of the lower wear zone or the total height of the ridge. Ridges and grooves are sprayed abradable layers with variable symmetric and asymmetric cross-sectional profiles and planographic arrangements to redirect blade tip leakage flow and / or to facilitate manufacturing It is configured. In some embodiments, the groove width is about two-thirds to one-third of the ridge width or lower ridge width (if a multi-width stacked ridge is provided). In various embodiments, the lower zone of the ridge is optimized to increase the mechanical and thermal structural integrity, thermal resistance, thermal corrosion resistance and wear life of the abradable components and surfaces It has been. The ridge upper zone is formed above the lower zone and is optimized to minimize blade tip clearance and wear by making it easier to scrape than the lower zone. Various embodiments of the abradable component of the sprayed abradable layer provide easier scraping of the upper zone with an upper subbridge or tip having a smaller cross-sectional area than the lower zone rib structure. In some embodiments, the upper subridge or tip is configured to bend or otherwise flex upon small blade tip contact and / or to wear and / or shear upon larger blade tip contact. Has been. In other embodiments, the upper zone support or tip is worn only at those tips that are in local contact with one or more blade tips, while others outside the local wear zone remain intact. As such, it is pixelated into an array of upper wear zones. Although the upper zone portion of the ridge is worn, the upper zone portion is less prone to blade tip wear than conventionally known monolithic ridges. In some embodiments of the present invention, when the upper zone ridge portion is worn, the remaining lower ridge portion maintains engine efficiency by controlling blade tip leakage. When the local blade tip clearance is further reduced, the blade tip wears the lower ridge portion at that location. However, the relatively high ridge outside the local wear area of its lower ridge portion maintains a smaller blade tip clearance to maintain engine performance efficiency. Three or more layers of wear zones (eg, upper, middle and lower wear zones) can be used in abradable components constructed in accordance with embodiments of the present invention.

  In some inventive embodiments, the ridge and groove profile and planographic arrangement in the sprayed or additionally formed abradable layer are selected to reduce blade tip leakage and change the ridge cross section. It has been adjusted locally or globally across the abradable component by forming a multi-layer groove with a selective orientation angle and / or cross-sectional profile. In some embodiments, the abradable component surface plan graphic arrangement and ridge and groove contours provide improved blade tip leakage airflow control, but simpler manufacturing techniques than known abradable components Also promote.

  In some embodiments, the abradable component and its abradable surface are formed from a multi-layer sprayed or additionally formed ceramic material of known composition from a known layer pattern / Consists of dimensions. In some embodiments, the ridge is a spray of molten particles (without or through a mask), layer printing (eg, 3D printing, sintering, electron or laser beam deposition), or (located below) The abradable surface is constructed by a known additive process such as providing a ceramic or metal / ceramic material to a metal substrate (with or without additional support structure). Grooves are formed in voids between adjacent added ridge structures. In other embodiments, the grooves are formed by scraping or removing material from the sprayed substrate using known processes (eg, machining, grinding, water jet or laser cutting or any combination thereof). The groove wall forms a separate ridge. Combinations of added ridges and / or removed material grooves may be used in the embodiments described herein. The abradable component includes a known support structure adapted to couple to a turbine engine casing and a known abradable such as one or more layers of a bond coating base, a thermal coating, and a heat resistant top coating. It is comprised with surface material plasticity. For example, the upper wear zone may be a sprayed or additionally formed ablative having different plastic and physical properties than another sprayed layer or other sequential layer directly below the upper wear zone. Can be composed of double material.

  Various thermally sprayed metal support layer abradable component ridges and groove profiles and groove and ridge arrangements described herein are hereby described in connection with all possible combinations of embodiments and features of the present invention. Can be combined to meet the performance requirements of various turbine applications, even if not specifically described in detail.

Abradable Plane Graphic A typical abradable surface ridge and groove planar graphic pattern of an embodiment of the present invention is shown in FIGS. Unlike known abradable planographic patterns that are uniform across the entire abradable surface, many of the planographic pattern embodiments of the present invention have distinct forward upstream (zone A) and rear downstream patterns (zone B). A composite multi-groove / ridge pattern having These combined Zone A and Zone B ridge / groove array plan views are used to directly block gas flow leakage from the turbine blade pressure side to the blade suction side in the local blade leakage direction L. The gas flow trapped inside is directed in the direction of the downstream combustion flow F. The forward zone is generally between the leading edge and the chord middle of the blade of blade 92 at a cutoff point where a line parallel to the axis of turbine 80 is approximately tangential to the pressure side surface of the blade. It is prescribed. From a more general overview perspective, the axial length of the forward zone A is generally defined as about one-third to one-half of the overall axial length of the wing. The rest of the array pattern includes the rear zone B. In accordance with embodiments of the present invention, three or more axially oriented planar graphic arrays can be constructed. For example, front, middle and rear ridge / groove array plan figures can be constructed on the abradable component surface.

The embodiments shown in FIGS. 12-19, 21, 22, 34, 35, 37 and 57 have hockey stick-like planar graphic patterns. The grooves and ridges of the front upstream zone A are aligned substantially parallel (± 10%) to the combustion gas axial flow direction F in the turbine 80 (see FIG. 1). The grooves and ridges in the rear downstream zone B are oriented at an angle in the direction opposite to the blade rotation direction R. The range of angles is about 30% to 120% of the warp or trailing edge angle of the associated turbine blade 92. For design convenience, the downstream angle selection is determined by the turbine blade high pressure or low pressure average (linear average line) sidewall surface or warp angle (eg, angle α in FIG. 14 on the high pressure side beginning at Zone B and ending at the blade trailing edge). _B2 ), trailing edge angle (eg see angle α _{B1 in} FIG. 15); angle matching connection between leading edge and trailing edge (see eg angle α _{B1 in} FIG. 14); or α _B3 etc. Any of these blade geometry establishment angles can be selected to match any of the angles. The hockey stick-like ridge and groove arrangement plane figure pattern is formed on the abradable surface relatively easily like the known plane figure arrangement pattern that is completely horizontal or diagonal, but in the fluid flow simulation, the hockey stick shape The pattern produces less blade tip leakage than any of these known unidirectional planar graphic patterns. The hockey stick-like pattern is formed by known cutting / cutting or additive layer construction methods conventionally used to form known abradable component ridge and groove patterns.

In FIG. 12, the abradable component 160 is directed forward at an angle α _A within ± 10 degrees with respect to the axial turbine axial flow direction F corresponding to the turbine blade rotation axis or the abradable component support axis. Ridge / ridge tip 162A / 164A and groove 168A. The rear ridge / ridge tip 162B / 164B and groove 168B are oriented at an angle α _B that is approximately the trailing edge angle of the turbine blade 92. As shown schematically in FIG. 12, the front ridge 162A blocks the forward zone A blade leakage direction and the rear ridge 162B blocks the rear zone B blade leakage L. In order to block and prevent blade tip leakage L, horizontal spacer ridges 169 are periodically directed axially along the periphery of the abradable component surface 167 over the entire footprint of the blade 92. .

The embodiment of the abradable component 170 of FIG. 13 is similar to the embodiment of FIG. 12 and includes a forward partial ridge 172A / 174A and a groove 178A oriented substantially parallel to the turbine combustion gas flow direction F. On the other hand, the rear ridges 172B / 174B and the grooves 178B are oriented at an angle α _B that is approximately equal to the angle formed between the pressure side of the turbine blade 92 starting in zone B and the blade trailing edge. Similar to the embodiment of FIG. 12, to block and prevent blade tip leakage L, the horizontal spacer ridge 179 is axially along the periphery of the abradable component surface 167 throughout the footprint of the blade 92. Is directed periodically.

The embodiment of the abradable component 180 of FIG. 14 is similar to that of FIGS. 12 and 13, with the forward partial ridge 182A / 184A and groove 188A oriented substantially parallel to the turbine combustion gas flow direction F. While the rear ridge 182B / 184B and the groove 188B are selectively oriented at any angle α _B1 to α _B3 . The angle α _B1 is an angle formed between the front edge and the rear edge of the blade 92. As shown in FIG. 13, the angle α _B2 is substantially parallel to the portion of the high-pressure side wall of the turbine blade 92 that faces the rear zone B. As shown in FIG. 14, the rear ridge 182B / 184B and the groove 188B are actually oriented at an angle α _B3 that is approximately 50% of the angle α _B2 . Similar to the embodiment of FIG. 12, in order to block and prevent blade tip leakage L, the horizontal spacer ridge 189 extends axially along the circumference of the abradable component surface 187 over the entire footprint of the blade 92. Is directed periodically.

In the abradable component 190 embodiment of FIG. 15, the forward ridge 192A / 194A and groove 198A and angle α _A are similar to those of FIG. 14, but the rear ridge 192B / 194B and groove 198B are similar to FIG. Narrower spacing and width. The alternative angle α _B1 of the rear ridge 192B / 194B and groove 198B shown in FIG. 15 coincides with the trailing edge angle of the turbine blade 92, such as the angle α _B in FIG. As shown in FIG. 13, the actual angle α _B2 is substantially parallel to the portion of the high pressure sidewall of the turbine blade 92 that faces the rear zone B. Alternative angle α _B3 and horizontal spacer ridge 199 are consistent with those of FIG. 14, but other arrangements of angles or spacer ridges can be utilized.

  Alternative spacer ridge patterns are shown in FIGS. In the embodiment of FIG. 16, the abradable component 200 includes a full length spacer ridge 209 extending across the entire axial footprint of the turbine blade 92 and an additional forward spacer ridge 209A inserted between the full length ridges. Has an array. An additional forward spacer ridge 209A provides additional blockage of blade tip leakage at the portion of blade 92 near the leading edge. In the embodiment of FIG. 17, abradable component 210 has a pattern of full length spacer ridges 219 and an array of circumferentially offset front spacer ridges 219A and rear spacer ridges 219B. Circumferentially offset ridges 219A / B allow for continuous contact during sliding that can cause premature blade tip wear when blade 92 slides on the surface of abradable component 210 Provides periodic blockage or obstruction of blade tip leaks without the need for

  While an arrangement of horizontal spacer ridges has been described so far, other embodiments of the present invention include vertical spacer ridges. In particular, the embodiment of the abradable component 220 of FIGS. 18 and 19 has a front ridge 222A, and a groove 228A is provided between the front ridges 222A. These grooves are interrupted by a shifted forward vertical ridge 223A that connects the forward ridges 222A to each other. As shown in FIG. 18, the shifted front vertical ridge 223A forms a series of diagonal arrays that slope downward from left to right. The full length vertical spacer ridge 229 is oriented in the transition zone T between the front zone A and the rear zone B. The rear ridge 222B and groove 228B are oriented at an angle to complete a hockey stick-like planar graphic arrangement comprising the front ridge 222A and groove 228A. The shifted rear vertical ridge 223B is arranged in the same manner as the front vertical ridge 223A. The vertical ridges 223A / B and 229 generally cross the groove of the abradable component 220 from the front part to the rear part, which would otherwise occur in the case of the uninterrupted full length groove embodiment of FIGS. While impeding axial airflow leakage, it involves the potential drawback of increased blade tip wear at each potential scraping contact point with one of the vertical ridges. The offset vertical ridge 223A / B, as a compromise, periodically impedes axial airflow through the grooves 228A / B without introducing a potential 360 degree sliding surface for the turbine blade tip. . Potential 360 degree rubbing surface contact for a continuous vertical ridge 229 can be reduced by reducing the ridge vertical height relative to the ridge 222A / B or 223A / B, but the forward groove 228A and the rear groove 228B. Still provides some degree of axial flow obstruction in the transition zone T.

  FIG. 20 shows a simulated fluid flow comparison between a hockey stick-like ridge / groove pattern array plan (solid line) with continuous grooves and a split groove (dotted line) interrupted by a shifted vertical ridge. ing. The total blade tip leakage mass flux (the area under each line) is smaller for the split groove arrangement pattern than for the continuous groove arrangement pattern.

The staggered ridges that obstruct the air flow in the grooves may not be aligned vertically in the blade rotation direction R. As shown in FIG. 21, abradable component 230 connects ridge 233A that connects between successive rows of front and rear ridges and periodically blocks downstream flow in grooves 238A / B. With a pattern of respective forward and rear ridges 232A / B and grooves 238A / B interrupted by a / B angled pattern (α _A , α _B ). As in the embodiment of FIG. 18, the abradable component 230 has a continuous vertically aligned ridge 239 located at the transition between the front zone A and the rear zone B. The intersecting angled arrangement of ridges 232A and 233A effectively blocks local blade tip leakage L from the high pressure side 96 to the low pressure side 98 along the turbine blade axial length from the leading edge to the trailing edge. To do.

  The embodiments of spacer ridges 169, 179, 189, 199, 209, 219, 229, 239, etc. shown in FIGS. 12-19 and 21 have different relative heights in the same abradable component arrangement. And may have a different height than one or more of the other ridge arrangements in the component. For example, if the spacer ridge height is less than the height of the other ridges on the abradable surface, the spacer ridge will not contact the blade tip, but still airflow along the adjacent interrupted groove. Can function to disturb.

  FIG. 22 is an alternative embodiment of an abradable component 240 with a hockey stick-like planar graphic pattern having separate front zones A and rear zones B, or any vertical ridges to divide the zones from each other. The embodiment concept of the ridges 242A / B and the grooves 248A / B intersecting at the transition portion T is combined. That is, the grooves 248A / B extend from the leading or trailing edge of the abradable component 240 to the rearmost downstream edge (see arrows in the flow direction F) covered by the axial sweep of the corresponding turbine blade. The continuous composite groove is formed. The displaced vertical ridges 243A / B pass through each groove without potential continuous scraping contact between the abradable surface and the corresponding rotating blade at one axial position (in the direction of the rotating arrow R). Interrupt axial flow. However, the relatively long extension of the continuous linear groove 248A / B, interrupted only periodically by the small vertical ridges 243A / B, facilitates easy manufacture by water jet erosion or other known manufacturing techniques. provide. The abradable component 240 embodiment provides a good subjective design compromise between airflow performance, blade tip wear and manufacturability / cost.

  23-25 illustrate an embodiment of an abradable component ridge having a zigzag pattern and a groove plane graphic arrangement. A zigzag pattern is formed by adding one or more layers of material to the abradable surface substrate to form a ridge, or by forming grooves in the substrate, such as by a known laser or water jet cutting method Is done. In FIG. 23, the substrate surface 257 of the abradable component 250 has continuous grooves 258 formed in the substrate surface 257, starting at 258 ′ and ending at 258 ″, with alternating finger-like shapes. A pattern of ridges 252 located between the two is formed. Other groove and ridge zigzag patterns may be formed on the abradable component. As shown in the embodiment of FIG. 24, the abradable component 260 was directed to a diagonal of a continuous pattern formed at the substrate surface 267, starting at 268 ′ and ending at 268 ″. It has a groove 268, leaving an angularly oriented ridge 262. In FIG. 25, abradable component embodiment 270 has a V-shaped or hockey stick-shaped double zone multi-groove pattern formed in substrate surface 277 by a pair of grooves 278A and 278B. Groove 278 begins at 278 'and ends at 278 ". To complete the V-shaped or hockey stick-like pattern on the entire substrate surface 277, a second groove 278A starting at 278A ′ and ending at 278A ″ is formed in the lower left portion of the abradable component 270. Has been. As was done in the abradable embodiment of FIGS. 12-19, 21 and 22, the flow direction forward and rear ridges 272A and 272B of the respective blade tip leaks L are respectively forward and rearward of the abradable surface 277. It is formed in a zone. The grooves 258, 268, 278 or 278A may not be formed continuously, and to prevent gas flow through the entire axial length of the grooves, the ridges 223A / B of the embodiment of FIGS. Such a blocking ridge may be provided.

FIGS. 26-29 illustrate embodiments of abradable component ridges and groove plane graphic arrangements having an overlaid loop pattern. The overlaid loop pattern forms a groove in the substrate by adding one or more layers of material to the abradable surface substrate to form a ridge, or by a known laser or water jet cutting method or the like. Formed by. The abradable component 280 embodiment of FIG. 26 has an array of vertically oriented loop patterns 281 separated by horizontally oriented spacer ridges 289. Each loop pattern 281 has overlapping grooves 288A-288E and corresponding complementary ridges including a central ridge 282A and loop ridges 282B-282E. In FIG. 27, the abradable component 280 ′ has a pattern of overlapping loops 281A in the front zone A and overlapping loops 281B in the rear zone B. Overlapped loops 281A and 281B are separated by a spacer ridge in both the horizontal direction 289 and the vertical direction 289A. In the abradable embodiment 280 ″ of FIG. 28, the horizontal portion of the overlaid loop 281 ″ is oriented at an angle α. In the abradable embodiment 280 ′ ″ of FIG. 29, the overlapped, generally horizontal or axial loops 281A ′ ″ and 281B ′ ″ are each in separate front zone A and rear zone B arrangements. Arranged at angles α _A and α _B. The forward and backward angles, as well as the loop dimensions, may be varied to minimize blade tip leakage in each zone.

FIGS. 30-33 illustrate an embodiment of an abradable component ridge and groove plan view arrangement having a spiral maze pattern similar to the overlaid loop pattern. The maze pattern is formed by adding one or more layers of material to the abradable surface substrate to form a ridge. Alternatively, as shown in these related drawings, the maze pattern is formed by forming grooves in the substrate, such as by known laser or water jet cutting methods. The embodiment of the abradable component 290 of FIG. 30 has an array of vertically oriented maze patterns 291 that are vertically oriented, separated by horizontally oriented spacer ridges 299, each starting at 291A and ending at 291B. Have. In FIG. 31, the abradable component 290 ′ has a pattern of overlapping mazes 291 </ b> A in the front zone A and overlapping mazes 291 </ b> B in the rear zone B. Overlapped mazes 291A and 291B are separated by spacer ridges in both the horizontal direction 299 ′ and the vertical direction 293 ′. In the abradable embodiment 290 ″ of FIG. 32, the horizontal portion of the superimposed maze 291 ″ is oriented at an angle α. In the abradable embodiment 290 ′ ″ of FIG. 33, the substantially horizontal portions of the mazes 291A ′ ″ and 291B ′ ″ have their respective angles α _A and α _{B in} separate front zone A and rear zone B arrays. While the substantially vertical portion is aligned with the blade rotation sweep. The forward and backward angles α _A and α _B , and the maze dimensions may be varied to minimize blade tip leakage in each zone.

34 and 35 show separate and distinct multi-arrayed ridges 302A / 302B in the respective forward zone A and rear zone B, connected by a pattern of corresponding curved ridges 302T and grooves 308T in the transition zone T. It relates to an embodiment of an abradable component 300 comprising a groove 308A / 308B pattern. In this exemplary embodiment pattern, the grooves 308A / B / T are formed as closed loops in the surface of the abradable component 300 that surround the corresponding ribs 302A / B / T. Spacing between ribs S _RA , S _RB and S _RT and corresponding groove spacings to minimize local blade tip leakage or to compensate for various local abradable surface erosion rates May vary axially and vertically across the component surface, which results in an asymmetric ridge surface area density.

In an alternative embodiment of Figure 64, local abradable surface area density of the abradable component 1300, has been varied by locally changing the ridge width W _R, the ridges in the rear zone B It has a wider ridge 1302A in the front zone A than 1302B, resulting in an asymmetric front zone A / back zone B surface area planographic pattern. There is a lower possibility of local ridge erosion, but there is a higher possibility of blade tip / substrate surface contact during engine operation, while reducing blade tip wear in the rear zone while in the front zone during engine operation. To compensate for greater ridge erosion, the front ridge 1302A has a larger surface area density than the rear ridge 1302B (and / or employs an abradable material with less machinability characteristics). In the embodiment of the abradable component 1300 of FIG. 64, successive rows of ridges have a constant ridge or rib spacing or pitch S _RA , S _RB and S _RT . That is, the width of the transition section ridge 1302T is locally reduced from the corresponding width of the combined front ridge 1302A to the corresponding width of the combined rear ridge 1302B. In order to maintain a constant ridge 1302 pitch, therefore, the width of the groove 1308 in each groove section 1308A / T / B is widened from front to back across the component 1300. The illustrated component 1300 has a closed loop in the surface of the abradable component 1300 surrounding the corresponding rib 1302A / B / T, similar to that of the component 300 shown in FIGS. It is prepared for. As described in more detail herein, local blade tip leakage and abradable surface density contact with the corresponding blade tip rib also cause subribs or subgrooves at the abradable surface ridge tip. Having (eg, see FIGS. 52-57), pixelated ridge tips (see, eg, FIG. 58) and / or tilting the blade tip surface relative to the rotating blade tips (eg, FIGS. 66-57) 69).

  FIG. 36 shows a comparable fluid dynamics simulation of comparable depth ridge and groove profiles in an abradable component. The solid line represents blade tip leakage in abradable components of the type of FIGS. The dotted line represents a conventional type of abradable component surface having only ribs and grooves oriented axially or horizontally. The dotted lines represent a conventional abradable component similar to the component of FIG. 7 with only diagonally oriented ribs and grooves aligned with the trailing edge angle of the corresponding turbine blade 92. Abradable components 300 and 1300 produce less blade tip leakage than the respective leakage of unidirectional abradable surface ridges and groove patterns of the type known in the art.

Abradable Plane Ridge and Groove Cross-Sectional Contour An abradable surface ridge and groove cross-sectional contour of a typical embodiment of the present invention is shown in FIGS. 37-41, 43-63 and 65-71. Unlike the known abradable cross-sectional contour pattern, which has a uniform height across the abradable surface, many of the cross-sectional contours of the present invention formed in the sprayed abradable layer have a distinct upper wear zone ( It has a complex multi-height / depth ridge and groove pattern with zone I) and lower wear zone (zone II). The lower zone II optimizes engine air flow and structural characteristics, while the upper zone I reduces blade tip clearance and wear to a minimum by being easier to scrape than the lower zone. Various embodiments of the abradable component provide easier scraping of the upper zone with an upper support or tip having a smaller cross-sectional area than the lower zone rib structure. In some embodiments, the upper subridge or tip is configured to bend or otherwise deflect upon small blade tip contact and to wear and / or shear upon larger blade tip contact. Has been. In other embodiments, the upper zone support or tip is worn only at those tips that are in local contact with one or more blade tips, while others outside the local wear zone remain intact. As such, it is pixelated into an array of upper wear zones. CMC / FGI that wears the upper zone portion of the ridge, but is less prone to blade tip wear than previously known monolithic ridges and requires a ring rating around the physical constraints of composite hollow ceramic sphere matrix orientation and diameter It provides a larger profile that forms the flexibility of the abradable component configuration. In some embodiments of the present invention, when the upper zone ridge portion is worn, the remaining lower ridge portion maintains engine efficiency by controlling blade tip leakage. When the local blade tip clearance is further reduced, the blade tip wears the lower ridge portion at that location. However, the relatively high ridge outside the local wear area of its lower ridge portion maintains a smaller blade tip clearance to maintain engine performance efficiency.

  With the progressive wear zone configuration of some embodiments of the present invention, the blade tip gap G can be reduced from previously acceptable known dimensions. For example, if the known acceptable blade gap G design specification is 1 mm, the height of the higher ridge in the wear zone I can be increased, thereby reducing the blade tip gap to 0.5 mm. . The lower ridge that establishes the boundary for wear zone II is set to a height such that the distal tip portion of the lower ridge is spaced 1 mm from the blade tip. In this form, for routine turbine operation, a more severe blade tip clearance G by 50% is established, allowing some potential wear caused by blade contact with the upper ridge in Zone I. Continuous local gradual blade wear in Zone II begins only when the blade tip reaches the lower zone, but in any case, the 1 mm blade tip gap G is the known blade tip gap specification. No worse than that. In some exemplary embodiments, the height of upper zone I is about one-third to one-third of the height of lower zone II.

The abradable component 310 of FIGS. 37-41 has alternating height curved ridges 312A and 312B protruding from the abradable surface 317 and structurally supported by the support surface 311. Grooves 318 separate alternating height ridges 312A / B and are defined by ridge sidewalls 315A / B and 316A / B. Wear zone I is formed from each tip 314A of the higher ridge 312A to each tip 314B of the lower ridge 312B. Wear zone II is formed from tip 314B to substrate surface 317. A blade gap G is maintained between the higher ridge tip 312A and the blade tip 94 under turbine engine operating conditions (FIGS. 39 and 40). Although blade gap G is maintained, the blade leakage L is the direction of rotation (arrow R) in the blade 92, from the higher pressure side of the (pressure at P _P) blades 96, or lower the blade 98 (in the pressure P _S) Move to the suction pressure side. Blade leakage L under blade tip 94 is partially trapped between the opposing pair of higher ridge 312A and middle lower ridge 312B, forming a blocking swirl pattern that further resists blade leakage. Rapid engine start mode or other reasons between blade tip 94 and abradable component 310 when blade tip gap G is reduced for any one or more blades due to turbine casing 100 distortion. Initial contact occurs at the higher ridge tip 314A. Further, while in Zone I, the blade tip 94 only rubs the alternately displaced higher ridge 312A. As the blade gap G gradually decreases, the higher ridge 312A is scraped until the higher ridge 312A is completely worn through zone I and begins to contact the lower ridge tip 314B in zone II. In Zone II, the turbine blade tip 94 rubs all of the remaining ridges 314A / B in the local wear zone, but in other local parts of the turbine casing, the reduction of the blade tip gap G is It may not occur and the upper ridge 312A may not change at full height. That is, the alternating height rib configuration of the abradable component 310 provides local wear in zones I and II, but in these local regions the aerodynamics of the blade tip gap G and blade tip leakage L. Control is maintained, where no distortion of the turbine casing 100 or blade 92 occurs. Where standard or rapid start or both engine operating modes are desired, the higher ridge 312A forms a primary layer of clearance, with the smallest blade tip gap G, typically with a lower ramp rate. Provides the best energy efficient clearance for machines that utilize or do not warm start. Generally, the ridge height H _RB for the lower ridge tip 314B is between 25% and 75% of the height H _RA of the higher ridge tip 314A. In the embodiment shown in FIG. 41, the centerline spacing S _RA between successive higher ridges 312A is equal to the centerline spacing S _RB between successive lower ridges 312B. Other centerline spacings and patterns of multi-height ridges with more than two ridge heights can be used.

Other embodiments of ridge and groove profiles with upper and lower wear zones are the steps of FIGS. 43 and 44 compared to the known single height ridge structure of the conventional abradable 150 in FIG. Shaped ridge contour. The known single height ridge abradable 150 has a base support 151 coupled to the turbine casing 100, a substrate surface 157, and inwardly sloping sidewalls 155 and 156 that terminate at a flat ridge tip 154. And a symmetric ridge 152. The ridge tips 154 have a common height and form opposed and spaced blade tips 94 and a blade tip gap G. A groove 158 is formed between the ridges 152. Ridge spacing S _R , groove width W _G , and ridge width W _R are selected for a particular application. For comparison, the stepped ridge profile of FIGS. 43 and 44 utilizes two separate upper and lower wear zones in the ridge structure.

43 has a support surface 321 and an abradable surface 327. The abradable surface 327 includes two separate ridges, namely a lower ridge 322B and an upper ridge 322A. And are arranged. Lower ridge 322B has a pair of side walls 325B and 326B which terminates at the flat portion 324B of the height H _RB. Upper ridge 322A is formed in flat portion 324B, protrudes from flat portion 324B, and has sidewalls 325A and 326A that terminate in distal ridge tip 324A of height H _RA and width W _R. The ridge tip 324A forms a blade tip gap G and a blade tip gap G spaced apart from each other. Wear zone II extends vertically from abradable surface 327 to flat portion 324B, and wear zone I extends vertically from flat portion 324B to ridge tip 324A. The two rightmost ridges 322A / B in FIG. 43 have an asymmetric profile with joined common sidewalls 326A / B, but the opposite sidewalls 325A and 325B are laterally offset from each other and have a width W _P Are separated by a flat portion 324B. The groove 328 is formed between the ridges 322A / B. The leftmost ridge 322A ′ / B ′ has a symmetrical contour. The lower ridge 322B ′ has a pair of converging sidewalls 325B ′ and 326B ′ that end at the flat portion 324B ′. Upper ridge 322A ′ is centered on flat 324B _′ , leaving an offset W _{P ′} of equal width relative to upper ridge sidewalls 325A ′ and 326A ′. Upper ridge tip 324A ′ has a width W _{R ′} . Ridge spacing S _R and groove width W _G is selected to provide a desired blade tip leakage air flow control. In some exemplary embodiments of the have been abradable component ridges and grooves contours described herein, the groove width W _G, is about two-thirds of 1-3 minutes in the lower ridge width . Although the ridges and grooves shown in FIG. 43 are symmetrically spaced, other spacing contours may be selected, including various ridge cross-sectional contours that form stepped wear zones I and II. .

  FIG. 44 shows another stepped profile abradable component 330 with ridges 332A / B having vertically oriented parallel side walls 335A / B and 336A / B. The lower ridge ends at the ridge flat portion 334B, and the upper ridge 332A is directed on the ridge flat portion 334B and ends at the ridge tip 334A. In some applications, it may be desirable to use vertically oriented side walls and flat tips / flats that form sharp corners for air flow control in the blade tip gap. The upper wear zone I is between the ridge tip 334A and the ridge flat portion 334B, and the lower wear zone is between the flat portion and the abradable surface 337. Similar to the abradable embodiment 320 of FIG. 43, the ridges and grooves shown in FIG. 44 are symmetrically spaced, but various ridge cross-sectional profiles forming stepped wear zones I and II Other spacing contours may be selected, including

In another replacement or type of stepped ridge configuration abradable component, separate upper and lower wear zones I and II may be used as shown in FIG. 45 in the abradable 340 profile. It may be formed by using the groove depth, groove width and ridge width. The lower rib 342B has a rib flat portion 344B that defines a wear zone II in relation to the abradable surface 347. The rib flat portion 344B supports a pair of opposed laterally lateral upper ribs 342A that end at a common height rib tip 344A. The wear zone I is defined between the rib tip 344A and the flat portion 344B. A convenient way of forming the contour of the abradable component 340, the abradable substrate flat surface, to cut the double depth grooves 348A and 348B to the respective depths D _GA and D _GB It is. Ridge spacing S _R , groove width W _{GA / GB} , and width W _R of ridge tip 344A are selected to provide the desired blade tip leakage air flow control. Although the ridges and grooves shown in FIG. 45 are symmetrically spaced, other spacing profiles may be selected, including various ridge cross-sectional profiles that form stepped wear zones I and II. .

  As shown in FIG. 46, one turbine application includes a vertically oriented sharp edged upstream sidewall 356 and a sloped opposite downstream sidewall 355 extending from the substrate surface 357 and ending at the ridge tip 354. It may be desirable to control blade tip leakage by employing an embodiment of an abradable component 350 having an asymmetric profile abradable ridge 352. Blade leakage L is initially resisted by the vertical side wall 356. However, a portion of the leaked air stream L is compressed between the ridge tip 354 and the opposing blade tip 94 as it flows from the high pressure blade side 96 of the blade to the low pressure suction blade side 98. This leakage flow follows a downwardly inclined ridge wall 355 where the leakage flow is redirected by the vertical wall 356 of the next downstream ridge opposite to the blade rotation direction R. The leaking air L now flowing in the opposite direction resists further incoming leaking air flow L in the blade rotation direction R. The dimensional criteria shown in FIG. 46 are consistent with the description of the criteria in the previously described figures. Although the abradable component embodiment 350 of FIG. 46 does not employ the progressive wear zones I and II of the other previously described abradable component contours, such a zone can be May be incorporated into the asymmetric profile rib embodiment described in FIG.

  By cutting the groove in the rib, a gradual wear zone can be incorporated into the asymmetric rib or any other rib profile, so that the remaining upright rib material that forms the sides of the groove cut remains. It has a smaller horizontal cross-sectional area than the rib located on the lower side. A groove orientation and profile that may be adjusted to enhance turbine engine air flow characteristics by reducing undesirable blade tip leakage is shown in the embodiment of FIG. 47 described herein below. . In this format, the sprayed abradable component surface is configured with both enhanced airflow characteristics and reduced potential blade tip wear. This is because the blade tip only contacts some parts of the upper wear zone I that are more easily scraped. Lower wear zone II remains in the lower rib structure below the groove depth. Now, other exemplary embodiments of ridge and groove profiles of abradable components used to form a progressive wear zone will be described. Structural features and component dimensional criteria in these additional embodiments that are common to the previously described embodiments are identified with the same series of reference numbers and symbols without further detailed description.

47 shows an abradable component 360 having a rib cross-sectional profile of the abradable component 350 of FIG. 46, the abradable component 360 having grooves formed between the ridge tips 364. FIG. It includes a dual level groove of groove 368B formed between 368A and ridge 362 up to substrate surface 367. Upper groove 368A has a wear zone I, while to form a transverse ridge of a shallower depth D _G, the remaining lower ridges 362 than the groove depth, the lower the wear zone II Have. In this abradable component embodiment 360, the upper groove 368A is oriented parallel to the longitudinal axis of the ridge 362 and is perpendicular to the surface of the ridge tip 364, but with airflow control. Other groove orientations, contours and depths may be employed to optimize and / or to reduce blade tip wear to a minimum.

In the embodiment of the abradable component 370 of FIG. 48, it is tilted back and forth at an angle γ with respect to the ridge tip 374 and has a depth _DGA and parallel groove sidewalls. The upper wear zone I is formed between the bottom of the groove 378A and the ridge tip 374, and the lower wear zone II is formed to the substrate surface 377 below the upper wear zone. In the alternative embodiment of FIG. 49, the abradable component 380 has an upper groove 388A with a rectangular profile inclined at an angle Δ relative to the longitudinal axis of the ridge 382 and the ridge sidewalls 385/386. Have. The illustrated upper groove 388A is also perpendicular to the surface of the ridge tip 384. The upper wear zone I is located above the groove depth D _GA, wear zone II is located to the substrate surface 387 below the the groove depth. For simplicity, the remaining structural features and dimensions are labeled in FIG. 48 and FIG. 49 with the same practices as the abradable table contour embodiment described above, and have the same functions, purposes and relationships described above. Have.

As shown in FIGS. 50-52, the upper groove may not have parallel sidewalls and may be oriented at different angles with respect to the ridge tip surface. In addition, the upper groove may be utilized in a ridge having a varied cross-sectional profile. The ridges of abradable component embodiments 390, 400 and 410 have symmetrical side walls that converge at the ridge tip. As in the previous embodiments having a double height grooves, each of the upper wear zone I, located from ridge tip to the bottom of the groove depth D _G, the lower wear zone II, from the groove bottom to the substrate surface positioned. In FIG. 50, the upper groove 398A is perpendicular to the substrate surface (ε = 90 °), and the groove side wall is expanded at an angle Φ. 51, the groove 408A is inclined at an angle + ε with respect to the substrate surface, and the groove 418A in FIG. 52 is inclined at −ε with respect to the substrate surface. In both abradable component embodiments 400 and 510, the upper groove sidewall is widened at an angle Φ. For simplicity, the remaining structural features and dimensions are labeled in FIGS. 50-52 with the same practices as the abradable surface contour embodiment described above, and have the same functions, purposes, and relationships described above. Have.

53-56, the illustrated abradable ridge embodiment also has a trapezoidal cross-sectional profile and various for selective airflow control while also having selective upper and lower wear zones. And a ridge tip with an upwardly oriented groove. In FIG. 53, an embodiment of the abradable component 430 has an array of ridges 432 with asymmetric cross-sectional profiles separated by a lower groove 438B. Each ridge 432 has a first side wall 435 inclined at an angle β ₁ and a second side wall 436 inclined at an angle β ₂ . Each ridge 432 has an upper groove 438A that is parallel to the ridge longitudinal axis and perpendicular to the ridge tip 434. The depth of the upper groove 438A defines the lower limit of the upper wear zone I, and the remaining height of the ridge 432 defines the lower wear zone II.

54-56, the cross-section of each ridge 422, 442 and 452 is trapezoidal with parallel sidewalls 425/445/455 and 426/446/456 oriented at an angle β. The right wall 426/446/456 is oriented to tilt in a direction opposite to the direction of blade rotation, thereby being captured in the intermediate lower groove 428B / 448B / 458B between two adjacent ridges. 46, the blade rotation against the blade tip leakage direction from the turbine blade upstream high pressure side 96 to the turbine blade low pressure suction side 98 as shown and described in the asymmetric abradable profile 350 of FIG. The direction is changed in the opposite direction. The orientation and contour of each upper groove 428A / 448A / 458A has also been modified to direct airflow leakage and form the upper wear zone I. Groove contour selectively, ranging from parallel side walls having no expansion, the depth D _G of changes in the angular orientation ε for changes to the ridge tip surface, to a negative or positive spreading angle Φ In, it is changed. In FIG. 54, the upper groove 428A is oriented perpendicular to the surface of the ridge tip 424 (ε = 90 °). In FIGS. 55 and 56, each upper groove 448A and 458A is oriented at an angle +/− ε with respect to its corresponding ridge tip surface.

FIG. 57 shows a plan view of an abradable component 460 having multi-level grooves and upper / lower wear zones, wherein the front A and rear B ridges 462A / 462B are at their respective angles α _{A / B.} It is separated by a directed lower groove 468A / B. 49. An array of front and rear upper partial depth grooves 463A / B of the type shown in the embodiment of FIG. 49 is formed in each array of ridges 462A / B at each angle β _{A / B.} It is directed across the ridge and full depth groove 468A / B. Upper partial depth grooves 463A / B define the vertical boundary of upper wear zone I of abradable component 460, and the remaining portions of the ridge below these partial depth upper grooves are: Specifies the vertical boundary of the lower wear zone.

  Due to the sprayed abradable component configuration, the cross-section and height of the sprayed abradable material in the upper wear zone I is shown at the top of the ridge, as shown in FIG. 58, in the CMC / FGI abradable configuration. To define an array of microribs or tips without the aforementioned geometric limitations of forming grooves around hollow ceramic spheres in the component configuration and the design advantage of using a metal abradable component support structure Can be configured to match various degrees of blade tip penetration. The abradable component 470 has the metal support surface 471 described above, and the lower groove and ridge arrangement forms the lower wear zone II. In particular, the lower ridge 472B has sidewalls 475B and 476B that terminate at the ridge flat 474B. Lower groove 478B is defined by ridge sidewalls 475B and 476B and substrate surface 477. The microribs or tips 472A are any other imposed on CMC / FGI abradable component designs by known addition processes or by forming an array of intersecting grooves 478A and 478C in the lower ridge 472B. It is formed in the lower ridge flat portion 474B without restriction of the hollow sphere integrity retaining geometry. In the embodiment of FIG. 58, the tip 472A has a square or other rectangular cross section defined by upstanding sidewalls 475A, 475C, 476A and 476C ending at a common height ridge tip 474A. Other cross-sectional planar shapes of the tip 472A can be utilized including, for example, a trapezoidal or hexagonal cross section. Tip arrays including various local cross sections and heights can also be utilized.

  In the alternative embodiment of FIG. 60, the distal rib tip 474A ′ of the upstanding pixel-like tip 472A ′ is sprayed having different physical properties and / or composition than the underlying sprayed material 482. It is composed of material 480. For example, the upper distal material 480 can be configured with ablation properties that are more or less likely to scrape than the lower material 482 (eg, more flexible or more porous or both). In this format, the blade tip gap G can be designed to be smaller than that used in previously known abradable components to reduce blade tip leakage, so that any locality to the material 480 can be achieved. A typical blade entry is less likely to wear the blade tip, even though such contact is more likely to occur. In this format, the turbine engine can be designed with a smaller blade tip clearance, which does not significantly affect blade wear and operates in the turbine engine's operating efficiency and in normal mode or fast start mode. Increase the ability to be.

The dimensional boundaries of the tip 472A and the groove 478A / C are identified in FIGS. 58 and 59 and are consistent with those described in the previous embodiment. Generally, the height H _RA of the tip 472A is in the range of about 20% to 100% of the blade tip gap G, or about one-third to one-third of the total ridge height of the lower ridge 472B and the tip 472A. is there. The cross section of the tip 472A is in the range of about 20% to 50% of the tip height H _RA. Tip material composition and surface density (quantified by centerline spacing S _{RA / RB} and groove width W _GA ) determine the abrasion resistance, heat resistance, structural stability and air flow characteristics of abradable component 470 Selected to equilibrate. For example, a plurality of small width tips 472A fabricated in a controlled density sprayed ceramic abradable provide high leakage protection against hot gases. This can be only in a high penetration tendency region or a complete engine set. Additional seals are required and it has been proposed that this be done not by increasing the width of the ridge, but through increasing multiple ridges that maintain the low strength of the ridge. Typical apex midline spacing S _{RA / RB} or apex 472A structure and array pattern density selection is such that the pixelated apex is in various modes as shown in FIGS. It makes it possible to respond to the varying depth of 94 penetrations.

In FIG. 61, there is zero or indeed a negative blade tip gap G. This is because the turbine blade tip 94 is in contact with the ridge tip 474A of the pixelated tip 472A. Contact penetration of the blade tip 94 deflects the pixelated tip 472A. In FIG. 62, there is a deeper blade tip penetration into the abradable component 470 and the tip 472A wears, breaks or shears the lower rib flat 474B, leaving the remaining blade tip gap therebetween. . In this form, there is minimal blade tip contact (if any) with the residual broken tip stub 472A, but the lower ridge 472B in wear zone II maintains air flow control of blade tip leakage. In FIG. 63, the blade tip 94 projects into the lower ridge flat 474B of the lower rib 472B in the wear zone II. Returning to the example of the starting of possible engine in standard mode or rapid start mode, in alternative embodiments, tip 472A may be arranged in a pattern of alternating height H _RA. That is, the higher tip is optimized for standard start and the lower tip is optimized for quick start. In the rapid start mode, the higher of the alternate tips 472A breaks, leaving the lower of the alternate tips to maintain the blade tip gap G. A typical sprayed abradable component having a frangible rib or tip has a ratio of height H _RA to width W _RA greater than one. Typically, the width W _RA measured at the highest point of the ridge or tip is 0.5-2 mm, and its height H _RA is determined by engine penetration needs and is a height to width ratio (greater than 1) ( H _RA / W _RA ) is maintained. Additional sealing is required, this is not by increasing the width W _RA of the ridge, through the increase in the plurality of ridges or apical (i.e., to maintain a low strength of the ridge, pointed end of the narrow Or a higher distribution density of ridges). For zones in engines that require a low speed abradable system, the ratio of ridge or tip width to groove width (W _RA / W _GA ) is preferably less than one. For engine abradable component surface zones or regions that typically do not require easy blade tip sharpness, the abradable surface profile is preferably maximized for aerodynamic sealing capability (E.g. small blade tip gap G and minimized by applying embodiments of the surface plan and cross-sectional profile of the present invention having a ridge / tip to groove width ratio greater than 1). Blade tip leakage).

Multiple modes of blade depth penetration into the circumferential abradable plane can occur at various locations in any turbine engine. Thus, the abradable surface configuration at any local circumferential position may be selectively varied to compensate for the possible extent of blade penetration. For example, referring again to the typical known circumferential wear zone pattern of the gas turbine engine 80 in FIGS. 3-6, the blade tip gap G at 3:00 and 6:00 positions is 12:00 and 9:00. It may be smaller than the wear pattern at the circumferential position. Given greater wear at the 12:00 and 6:00 positions, the lower ridge height H _RB can be selected to form the worst case minimum blade tip gap G, pixelated or Other upper wear zone I ridge structure heights _HRA , cross-sectional widths, and tip spacing densities are the possibility of distortion of the abradable component and case that causes the blade tip 94 to enter the abradable surface layer. At other circumferential positions of the turbine casing, such as low or minimal, one can choose to form a small “best case” blade tip gap G. Using the brittle ridge 472A of FIG. 62 as an example, during severe engine operating conditions (eg, when the engine is in rapid start mode), the blade 94 impacts the brittle ridge 472A or 472A ′ and the ridge is high It breaks under load, increases clearance only in the impact zone, and limits blade tip wear under suboptimal abradable conditions. In general, the ridge height of the upper wear zone I in the abradable component can be selected such that the ideal blade tip clearance is 0.25 mm. The 3:00 and 9:00 turbine casing circumferential wear zones (eg, 124 and 128 in FIG. 6) are likely to maintain the desired 0.25 mm blade tip clearance throughout the engine operating cycle. In the circumferential position, the possibility of distortion of the turbine casing / abradable component is high. The lower ridge height may be selected to set the ridge tip to an ideal blade tip gap of 1.0 mm, so that in higher wear zones, the blade tip is more than only into wear zone I. It wears deep and does not contact the lower ridge tip that sets the boundary for the lower wear zone II. Despite the best calculations, even if the blade tip continues to wear into wear zone II, the resulting blade tip wear operating conditions will not be worse than previously known abradable layer configurations. However, in the remainder of the local circumferential position along the abradable layer, the turbine engine has an undesirably increased wear at the blade tips with a lower blade tip gap G and thus higher operating efficiency. Works properly with little or no.

Sloped Angle Surface Ridge or Groove Pattern The embodiment of the abradable component of FIGS. 65-71 can be used to control blade edge airflow leakage out of sloped sidewalls, ridge tips or groove base surfaces. A ridge or groove pattern with one or more is employed. Embodiments having an inclined ridge tip also promote reduced wear on the blade tip. This is because these embodiments have a smaller potential abradable surface contact area with the blade tip as compared to embodiments with a flat ridge tip. Various embodiments previously described herein employed flat ridge tips with progressive wear zones for blade tip wear reduction and blade tip leakage control profiles. Recall that the abradable component 310 embodiment of FIG. 39 employs double height ridges 312A / 312B for wear reduction and blade tip leakage flow L control. In contrast, the abradable component 350 of FIG. 46 employs a tapered rib / ridge 352 profile with vertical sidewalls 356 and inclined sidewalls 355, which is tapered rib / ridge. More surface area is exposed when 352 is scraped vertically toward the groove base 357. The groove 358 formed by the opposed vertical and inclined sidewalls 356/355 creates a backflow L in the groove channel 357 to reduce tip leakage flow.

In the embodiment of FIG. 65, the abradable component 1310 has a protruding ridge 1312 with a flat ridge tip 1314 similar to that of the embodiment of FIG. However, the side walls 1315/1316 are inclined in the vertical direction or opposite to the rotational direction R of the blade 92 or have tips. The sloped side wall 1316 on the upstream side of the ridge 1312 (ie, the side facing the flow L) creates a backflow and forms a longer serpentine or labyrinth flow path for the leakage flow. The reverse flow and the longer flow path effectively reduce the leakage L flow rate. In addition, the connection of the inclined downstream side wall 1315 with the flat ridge tip 1314 increases the air flow volume downstream of the gap limiting portion between the ridge tip and the blade tip 94. The increased volume in the groove forms an expansion zone for the air flow L, which creates a vortex air flow L ₁ along the side wall connection to the groove base or floor 1317. Close. The air flow L ₁ resists the flow of the blade tip leakage L while increasing the distance of the entire flow path. The resistance due to backflow and the increased airflow distance effectively helps reduce the flow rate of the airflow leakage L.

Each abradable embodiment 1320, 1330, 1340 and 1350 of FIGS. 66-69 has inclined ridge tips 1324, 1334, 1344 and 1354 to abradable ridges 1322, 1332, 1342 and 1352, respectively. In addition, a blade tip gap having a variable width is generated across the ridge tip along the rotation direction R of the blade tip 94. Focusing on FIG. 66, the inclined ridge or rib tip 1324 effectively reduces the contact surface area of the corresponding abradable surface with the potential blade tip 94 compared to that of the ridge tip 1314 of FIG. ing. Contact between the initial local ridge tip 1314 and the blade tip 94 (if any) occurs only along the rightmost upstream edge of the tip at the junction with the sidewall 1326, and the contact surface area is determined by As the gap between the abradable tip / blade tip becomes narrower, it expands. That is, if desired, the sloped ridge tip surface 1324 can be used to provide a stepped, multi-level, sub-grooved, or progressive abdomen component ridge profile without the need to fabricate a ridge profile. Effectively provide braidable wear zones. The sloped ridge tip 1324 provides additional vortex airflow L in the expanded gap airflow expansion zone downstream of the narrowest gap restriction when the leaked airflow L opens to a less narrowed flow space. ₂ is advantageously produced. The additional air flow region L ₂ supplements the vortex air flow region L ₁ at the connection between the side wall 1325 and the groove base 1327. The combination of air flow regions L ₁ and L ₂ creates a larger cumulative back flow and energy dissipation of the tip leakage flow, forming a longer serpentine or labyrinth flow path for the leakage flow. The embodiment of the abradable component 1330 of FIG. 67 adds a slanted groove base 1337 to the groove 1338 and provides a larger leakage air flow L compared to the contour of the flat groove base 1327 of the groove 1328. An expansion space is further formed. The angled groove base 1337 also directs the leakage air flow L away from the blade tip gap until it is suddenly redirected at the next upstream ridge sidewall 1326 connection. In each abradable component embodiment 1340 and 1350 of FIGS. 68 and 69, the respective ridge tips 1344 and 1354 are tilted in the opposite direction to that of FIGS. In each of these embodiments, the blade tip clearance narrows along the blade rotation direction R, so that the leakage air flow L is limited and then rapidly expands once it passes through the connection of the downstream side wall 1345/1355. Then, the vortex-like air flow L ₁ is generated. Other structural features of abradable components 1320, 1330, 1340 and 1350 are indicated using the same reference number convention as that of component 1310 of FIG.

Each of the abradable components 1360 and 1370 of FIGS. 70 and 71 includes a ridge side wall inclined in a direction opposite to the blade rotation direction R / airflow leakage direction L and a stepped ridge tip. And ridge wear zones on the upper I and lower II of the previous embodiment and the enhanced airflow of embodiments 1320, 1330, 1340 and 1350 of FIGS. 66-69, respectively. Combined with control of leakage L. The abradable component 1360 includes a base substrate 1361 that supports the stepped abradable ribs 1362A / B and the groove base 1367. The stepped rib lower portion 1362B forms the lower wear zone II, while the upper portion 1362A forms the upper wear zone I, providing a variable machinability surface area. This is because the ribs are worn in the local area by rubbing contact with the tip 94 of the rotating blade 92. The rib upstream side wall defines a bent composite angle profile with a lowermost portion 1366B that is inclined in the blade rotation direction R, whereas the uppermost portion 1366A is what the blade rotation direction is. It is tilted in the opposite direction. The bent angle of inversion, while causing a backflow air recirculation leakage flow L, 1364B from stepped rib tip 1364A along the sidewall portion 1364A may rise to air flow expansion in the eddy current flow zone L ₂ Close. As described above, the vortex flow zone L ₂ resists the downstream leakage flow L and increases the effective meandering or labyrinth flow path of the leakage flow L. A further increase in the flow expansion volume in the region near the connection between the lower sidewall 1365B and the groove base 1367 results in the vortex flow zone L ₁ described above. In embodiment 1370, the slanted groove base 1377 in the groove 1378 further creates a larger leakage air flow L expansion space compared to the flat groove base 1367 of the groove 1368 contour of FIG. The angled groove base 1377 also directs the leakage air flow L away from the blade tip gap until it is suddenly diverted at the connection of the next upstream ridge bend angle sidewall 1376B / 1376A. Although not shown, the blade / abradable gap airflow leak L and the abradable surface area are further abradable by inclining one or both of the respective ridge tips 1364A / 1364B or 1374A / 1374B. Changes can be made selectively in either component 1360 or 1370.

Advantages of Various Embodiments Various embodiments of turbine abradable components are described herein. Many embodiments have separate forward and backward planar graphic ridge and groove arrangements for local blade tip leakage and other air flow control across the axial span of the rotating turbine blade. The ridge and groove patterns and arrangements of many embodiments are configured with straight segments that are easy to manufacture, sometimes with curved transitions between the front and rear zones. Many embodiments form a gradual vertical wear zone in the ridge structure so that the formed upper zone is more easily scraped than the lower wear zone. The upper zone, which is scraped relatively easily, reduces the risk of blade tip wear, but creates and preserves the desired small blade tip gap. The lower wear zone focuses on air flow control, thermal wear and relatively lower thermal wear. In many embodiments, both local air flow control and multiple vertical wear zones are incorporated into the abradable component.

  While various embodiments including the teachings of the present invention are shown and described herein, those skilled in the art can readily devise many other modified embodiments that also include these teachings. The invention is not limited in its application to the details of exemplary embodiments of the construction and arrangement of components shown in the detailed description or illustrated in the drawings. The invention is capable of other embodiments and of being practiced or carried out in various forms. For example, the various ridge and groove profiles may be incorporated in different planar graphic arrangements that may be varied locally along the periphery of a particular engine application. In addition, it should be understood that the expressions and terms used herein are for purposes of explanation and should not be considered limiting. That is, the use of “including”, “including” or “having” and variations thereof herein are intended to encompass the items listed below, equivalents thereof, and additional items. Unless explicitly stated or limited otherwise, the terms “attached”, “coupled”, “supported” and “coupled” and variations thereof are widely used and are both direct and indirect Includes attachment, coupling, support and coupling. Further, “coupled” and “coupled” are not limited to physical or mechanical coupling or coupling.

Claims (10)

A turbine engine,
A turbine housing;
A rotor having blades rotatably mounted within the turbine housing, the distal tip of the blade forming a blade tip circumferential movement path in a blade rotation direction and axially with respect to the turbine housing the blade tip, a leading edge is substantially parallel to the surface tangent to the corresponding turbine blade rotation axis has a chord intermediate cut-off point on the pressure-side concave surface, a trailing edge, a rotor When,
An abradable component, and
The abradable component is:
A adapted support surfaces to be coupled to the turbine casing circumference surrounding the turbine blade rotation axis, an upstream end and a downstream end, so as to be oriented parallel to the corresponding turbine blade rotation axis A support surface having a support surface axis adapted to,
Wherein a connected abradable substrate on the support surface (1300), defined by a pair of front linear segments portions connected by a transition portion (T) and the rear linear segments moiety (A, B), the groove An abradable substrate (1300) comprising a substrate surface having a composite angular plane graphic pattern of ridges (1302, 1302A, 1302B) projecting vertically and ridges;
Radial and axial directions of the intended turbine blade chord mid-cut-off travel path, starting near the upstream end of the support surface and oriented within an angular range of ± 10 degrees relative to the support surface axis Each forward linear segment portion (A) ending between the support surface ends upstream of the projection position;
Each rear alignment that begins downstream of the intended turbine blade chord mid cut-off point and is oriented angularly opposite to the corresponding turbine blade rotation direction and ends near the downstream end of the support surface A segment portion (B),
Front ridge in the front linear segment portion (A) (1302A) is characterized by having a high surface area density than the rear ridge (1302B) in the rear linear segment portion (B), the turbine engine. More to form a large surface density, further comprising a wide of the front ridge (1320A) of the rear ridge (1302B), the turbine engine of claim 1, wherein the front ridge. To match the width of each of the corresponding connected the front ridge and the width of the rear ridge further has a ridge width which narrows from the front to the rear (W _R) in the transition section, the turbine engine of claim 2, wherein . Defining a curved plane figure further comprises ridges and grooves in the transition section (T), the turbine engine of claim 2 wherein. At least a plurality of portions having a tip projecting distal inclined relative to the support surface, the turbine engine of claim 2 wherein said ridge. The ridge and groove have a continuous zigzag groove pattern, the turbine engine of claim 2 wherein. The ridge and groove are at a constant spacing pitch _{(S RA, S RB, S} RT) having a turbine engine of claim 2 wherein. The ridge and groove are at a constant spacing pitch _{(S RA, S RB, S} RT) having a turbine engine of claim 1, wherein. The ridge and groove have a continuous zigzag groove pattern, the turbine engine of claim 1, wherein. Each front ridge of the front linear segment portion, said being oriented parallel to the supporting surface axis, the turbine engine of claim 1, wherein.

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