Patent Description:
Turbine systems are continuously being modified to increase efficiency and decrease cost. One method for increasing the efficiency of a turbine system includes increasing the operating temperature of the turbine system. To increase the temperature, the turbine system must be constructed of materials which can withstand such temperatures during continued use.

In addition to modifying component materials and coatings, a common method of increasing temperature capability of a turbine component includes the use of cooling features. For example, one type of cooling feature includes an impingement member having apertures formed therein. The impingement member directs cooling fluid through the apertures and towards a surface that is intended to be cooled. However, it is often difficult to control the flow of the cooling fluid once it exits the apertures, particularly in the presence of cross-flow between the impingement member and the surface to be cooled. Furthermore, various components generally include portions which can be difficult to reach with cooling fluid flow from the impingement member.

To ensure sufficient cooling of the component, an increased amount of cooling fluid is typically passed through the apertures in the impingement member. As the cooling fluid is often provided from the compressed air in a turbine engine, passing an increased amount of cooling fluid through the apertures removes an increased portion of the compressed air prior to reaching the combustor. Removing an increased portion of compressed air may decrease efficiency and increase operating cost of the turbine engine.

<CIT> discloses a tubular insert for impingement cooling a wall part of a turbine blade.

Multiple conically shaped tubes are arranged on a support and open towards the wall part to be cooled in a perpendicular or oblique direction. The tubes project into a space between the support and the wall part.

<CIT> discloses an acoustic resonator with impingement cooling tubes. The cooling tubes are attached to an inside face of the resonator and may have various cross sectional sizes and shapes.

<CIT> discloses an impingement cooling of combustor liners. Nozzles are attached into perforations of an outer liner and project into a cooling space towards an opposing inner liner of the combustor. A nozzle may have multiple air holes.

<CIT> discloses an impingement cooling arrangement in a gas turbine engine, e.g., in an aerofoil. Some of the impingement holes provided in an inner wall of the aerofoil include a deflector wall projecting into an inner passageway towards an outer suction wall.

<CIT> discloses a cooled component for a gas turbine. A perforated plate is provided with interspaced perforations located in front of a cooling surface, wherein beads run transversally to one another on the perforated plate in order to maintain an optimal cooling action. The arrangement can be manufactured, among others, by laser powder welding.

<CIT> discloses a cooling structure with an improved cooling efficiency. A first plate part and a second plate part disposed to be separated from the first plate part include a space therebetween. In the cooling structure a fluid for cooling is guided into the space through a plurality of guide parts formed to the second plate part to cool the first plate part. The guide parts are nozzles having guide holes opened toward the first plate part and project into the space.

<CIT> discloses a gas turbine combustion chamber. A perforated plate and a baffle surface form a cooling duct, and tubelets are arranged in the cooling duct on holes formed in the perforated plate in such a way that the air to be deflected strikes the baffle surface at right angles. The height of the tubelets increases in the cross-flow direction in such a way that the distance of the tubelets from the baffle surface is constant over the entire length of the cooling duct.

<CIT> discloses an impingement plate for damping and cooling shroud assembly intersegment seals. Impingement holes are formed across an area of the impingement plate, and a cooling and damping section includes conical channels shaped to accelerate cooling flow through the impingement plate.

<CIT> discloses a cooling for double wall structures such as in turbine vane airfoils. Multiple impingement ports are arranged along an impingement rail extending axially within a cavity defined by a respective jet issuing wall and a target wall of the structure.

Other features and advantages of the present invention will be apparent from the following more detailed description, taken in conjunction with the accompanying drawings which illustrate, by way of example, the principles of the invention.

Wherever possible, the same reference numbers will be used throughout the drawings to represent the same parts.

Provided are a impingement sleeve, a turbine nozzle, and a method of forming an impingement sleeve.

Embodiments of the present disclosure, for example, in comparison to concepts failing to include one or more of the features disclosed herein, increase cooling efficiency, decrease cooling fluid use, increase control of fluid flow, provide fluid flow to difficult to reach areas, increase heat transfer, facilitate use of increased operating temperatures, provide concentration of fluid flow on hot spots, and combinations thereof.

The disclosed article <NUM> is an impingement sleeve for directing fluid flow within a turbine nozzle. The impingement sleeve <NUM> includes one or more apertures <NUM> formed therein. For example, the impingement sleeve can have a plurality of apertures <NUM>.

Turning to <FIG>, the apertures <NUM> are formed in a body portion <NUM> that defines and/or separates an inner region <NUM> and an outer region <NUM>. The apertures <NUM> fluidly connect the inner region <NUM> to the outer region <NUM>, providing fluid flow between the inner region <NUM> and the outer region <NUM>. For example, in one embodiment, the apertures <NUM> extend between an inner surface <NUM> and an outer surface <NUM> of the body portion <NUM>, facilitating a flow of cooling fluid from the inner region <NUM> to the outer region <NUM>.

According to the invention one aperture <NUM> has a non-round geometry. Further apertures <NUM> may include any suitable geometry for fluidly connecting the inner region <NUM> and the outer region <NUM>. Suitable geometries include, but are not limited to, circular, substantially circular, round, substantially round, oval, non-round, square, triangular, star shaped, polygonal, tear drop, varied, irregular, any other geometrical shape, or a combination thereof. The geometry of the apertures <NUM> may be uniform, substantially uniform, or varied throughout the article <NUM>, with the geometry of each of the apertures <NUM> being the same, substantially the same, and/or different from one or more other apertures <NUM> in the article <NUM>. Additionally, the apertures <NUM> include any suitable orientation and/or spacing for facilitating cooling flow. Suitable spacing between the apertures <NUM> includes, but is not limited to, even, uniform, varied, gradient, and/or sectioned, with the spacing of each of the apertures <NUM> being the same, substantially the same, and/or different from one or more other aperture <NUM>.

The geometry and/or spacing of the apertures <NUM> at least partially determines a cooling profile of the article <NUM>. The cooling profile refers to parameters of fluid flow throughout the article <NUM>, such as, but not limited to, concentration, distribution, and/or rate of fluid flow through the apertures <NUM>. For example, in one embodiment, an increased number of apertures <NUM> and/or a decreased spacing between the apertures <NUM> increases an amount and/or concentration of cooling flow in a particular section. In another embodiment, a variation in size of the apertures <NUM> varies an amount of cooling flow through each of the apertures <NUM> and/or varies a rate of fluid flow through each of the apertures <NUM>. In a further embodiment, varying the geometry and/or spacing of the apertures <NUM> along the article <NUM> varies the cooling profile throughout the outer region <NUM>. Referring to <FIG>, the article <NUM> also includes one or more conduits <NUM> extending from the outer surface <NUM> of the body portion. Each of the conduits <NUM> is positioned at one of the apertures <NUM> to controllably direct fluid from the inner region <NUM> to the outer region <NUM>. For example, in one embodiment, an opening in the conduit <NUM> is aligned or substantially aligned with the aperture <NUM> to controllably direct the fluid flowing through the aperture <NUM> into the outer region <NUM>. The article <NUM> includes any suitable number of conduits <NUM> up to an amount equal to the number of apertures <NUM>. Although shown as including three rows of conduits <NUM>, as will be appreciated by those skilled in the art, the article <NUM> may include an increased or decreased number of conduits <NUM>, the number of conduits <NUM> being equal to or less than the number of apertures <NUM>.

According to the invention, the cross-sectional geometry of the interior surface of the conduit extending from an outer surface of the body portion at the aperture with the non-round geometry is a star shaped cross-sectional geometry, that extends the non-round geometry of the aperture.

An interior and/or exterior surface of further conduits <NUM> may include any suitable cross-sectional geometry different from each other and/or the geometry of the apertures <NUM>. Suitable geometries are uniform, substantially uniform, or varied throughout the article <NUM>, and include, but are not limited to, circular, substantially circular, round, substantially round, non-round, star shaped, oval, square, triangular, polygonal, tear drop, varied, irregular, any other geometrical shape, or a combination thereof. For example, in one non-claimed embodiment, as illustrated in <FIG>, the conduit <NUM> includes a round or substantially round cross-sectional geometry <NUM> that extends the geometry of the aperture <NUM>. The conduit <NUM> includes a star shaped cross-sectional geometry <NUM>, that extends the non-round geometry of the aperture <NUM>. In a non-claimed embodiment, the round, substantially round, non-round, and/or other cross-sectional geometry of the conduit <NUM> may differ from the geometry of the aperture <NUM>, such as, for example, a non-round conduit positioned over a round or substantially round aperture. Other aspects of the conduits <NUM>, such as, but not limited to, length, diameter, spacing, and/or angle are also the same as, substantially the same as, or different from the corresponding aspects of the apertures <NUM>, and may be uniform, substantially uniform, or varied throughout the article <NUM>.

The one or more conduits <NUM> are configured to maintain, extend, and/or modify the flow of fluid from the apertures <NUM>. The configuration of the conduits <NUM> is selected to provide desired impingement flow and/or cooling. For example, in one embodiment, the conduits <NUM> having the same or substantially the same geometry as the apertures <NUM> extend the orientation of the apertures <NUM> to maintain the fluid flow through at least a portion of the outer region <NUM>. In another embodiment, the conduits <NUM> differ from the orientation of the apertures <NUM> to modify a direction of the fluid flow from the apertures <NUM>. In a further embodiment, the conduits <NUM> having differing geometries from the apertures <NUM> modify a profile and/or direction of the fluid flow from the apertures <NUM>. Additionally the conduits <NUM> may include an orifice feature <NUM> opposite the outer surface <NUM> of the article <NUM>. The orifice feature <NUM> includes any suitable feature for modifying fluid flow exiting the conduit <NUM>, such as, but not limited to, a contraction (e.g., a slot and/or partial closing), multiple holes formed in the conduit <NUM>, a narrowing (e.g., a funnel shape), or a combination thereof.

Turning to <FIG>, the article <NUM>, which is the impingement sleeve, is configured for insertion and/or positioning within a component <NUM>, which is the turbine nozzle. When inserted and/or positioned within the component <NUM>, the outer region <NUM> of the article <NUM> extends between the outer surface <NUM> of the article and an inner surface <NUM> of the component <NUM>. Additionally, when the article <NUM> is inserted and/or positioned within the component <NUM>, the flow of fluid through the apertures <NUM> provides impingement cooling of the component <NUM>. For example, a cooling fluid provided to the inner region <NUM> of the article <NUM> may pass through the apertures <NUM> and/or conduits <NUM> to the outer region <NUM> where the cooling fluid contacts the inner surface <NUM> of the component <NUM> to cool the component <NUM>. The orientation and/or spacing of the apertures <NUM> and/or the conduits <NUM> at least partially determines an amount, direction, and/or concentration of the cooling fluid passing from the inner region <NUM> to the outer region <NUM>.

By maintaining, extending, and/or modifying the flow of fluid from the apertures <NUM>, the conduits <NUM> increase cooling efficiency of the article <NUM>, provide cooling of the component <NUM> with a decreased amount of fluid, and/or facilitate the use of increased operating temperatures. For example, by extending a fluid outlet from the aperture <NUM> at the outer surface <NUM> of the article <NUM> to an end of the conduit <NUM> opposite the outer surface <NUM>, the conduits <NUM> provide a distance between the fluid outlet and the inner surface <NUM> of the component <NUM> independent of the dimensions of the body portion <NUM>. In one embodiment, the conduits <NUM> permit the use of a relatively smaller body portion <NUM>, which increases a size of the outer region <NUM> between the outer surface <NUM> of the body portion <NUM> and the inner surface <NUM> of the component <NUM>. In another embodiment, the increased size of the outer region <NUM> decreases cross-flow velocity in the outer region <NUM>. The decreased cross-flow velocity in the outer region <NUM> decreases an effect of cross-flow on impingement fluid flow, facilitates increased control over the impingement fluid flow, increases cooling efficiency, and/or facilitates cooling with a decreased amount of fluid.

Additionally or alternatively, the conduits <NUM> decrease a distance between the fluid outlet and the inner surface <NUM> of the component <NUM>. The decreased distance between the fluid outlet and the inner surface <NUM> of the component <NUM> decreases an exposure of the fluid to cross-flow within the outer region <NUM> and/or increases contact between the fluid and the inner surface <NUM>, which increases cooling efficiency. Additionally or alternatively, the conduits <NUM> may be oriented to direct and/or concentrate the flow of fluid toward specific portions of the component <NUM>, such as, but not limited to, hot spots, a hot side wall of the component <NUM>, hard to reach portions including a trailing edge portion of a turbine nozzle (see <FIG>), or a combination thereof. The decreased distance between the fluid outlet of the conduits <NUM> and/or the directing and/or concentrating of the flow of fluid through the conduits <NUM> facilitate use of a decreased amount of cooling fluid, increase cooling efficiency of the cooling fluid as compared to apertures <NUM> alone, facilitate higher temperature operation of the component <NUM>, increase thru put, and/or increase operating efficiency.

In one embodiment, forming the article <NUM> and/or the conduit(s) <NUM> includes any suitable additive manufacturing method. Referring to <FIG>, in another embodiment, the additive method <NUM> includes making and/or forming net or near-net shape articles <NUM> and/or conduits <NUM>. As used herein, the phrase "near-net" refers to the article <NUM> and/or conduits <NUM> being formed with a geometry and size very similar to the final geometry and size of the article <NUM> and/or conduits <NUM>, requiring little or no machining and processing after the additive method <NUM>. As used herein, the phrase "net" refers to the article <NUM> and/or conduits <NUM> being formed with a geometry and size requiring no machining and processing. For example, in one embodiment, the additive method <NUM> includes making the article <NUM> including the one or more aperture <NUM> and/or the one or more conduit <NUM>. The additive method <NUM> provides any net or near-net shape to the articles <NUM>, the aperture(s) <NUM>, and/or the conduit(s) <NUM>. Additionally or alternatively, the additive method <NUM> includes forming the article <NUM> separate from the one or more conduit <NUM>, then securing the one or more conduit <NUM> to the article <NUM>. Although described with regard to the aperture(s) <NUM> being formed during the additive method <NUM>, as will be appreciated by those skilled in the art, at least one of the aperture(s) <NUM> may be machined into the article <NUM> after the additive method <NUM>, without affecting the net or near-net geometry of the article <NUM>.

The additive method <NUM> includes any manufacturing method for forming the article <NUM> and/or conduits <NUM> through sequentially and repeatedly depositing and joining material layers. Suitable manufacturing methods include, but are not limited to, the processes known to those of ordinary skill in the art as Direct Metal Laser Melting (DMLM), Direct Metal Laser Sintering (DMLS), Laser Engineered Net Shaping, Selective Laser Sintering (SLS), Selective Laser Melting (SLM), Electron Beam Melting (EBM), Fused Deposition Modeling (FDM), or a combination thereof. In one embodiment, for example, the additive method <NUM> includes providing a metal alloy powder <NUM> (step <NUM>); forming an initial layer <NUM> with the metal alloy powder <NUM> (step <NUM>); sequentially forming an additional layer <NUM> over the initial layer <NUM> with the metal alloy powder <NUM> (step <NUM>); and joining the additional layer <NUM> to the initial layer <NUM> to form the article <NUM> and/or conduits <NUM> (step <NUM>). In another embodiment, the additive method <NUM> includes repeating the steps of sequentially forming the additional layer <NUM> over a previously formed layer and joining the additional layer <NUM> to the previously formed layer (step <NUM>) until the article <NUM> and/or conduit(s) <NUM> having a predetermined thickness and/or a predetermined shape are obtained. The previously formed layer includes any portion <NUM> of the article <NUM> and/or conduits <NUM> including the initial layer <NUM> and/or any other additional layer(s) <NUM> directly or indirectly joined to the initial layer <NUM>.

The initial layer <NUM> includes a preselected thickness <NUM> and a preselected shape, which includes at least one first opening <NUM>. Each of the additional layers <NUM> includes a second preselected thickness <NUM> and a second preselected shape, the second preselected shape including at least one second opening <NUM> corresponding to the at least one first opening <NUM> in the initial layer <NUM>. The second preselected thickness <NUM> and/or the second preselected shape may be the same, substantially the same, or different between one or more of the additional layers <NUM>. When joined, the preselected thickness <NUM> of the initial layer <NUM> and the second preselected thickness <NUM> of the additional layer(s) <NUM> form a combined thickness <NUM> of the portion <NUM>. Additionally, the at least one first opening <NUM> and the corresponding at least one second opening <NUM> form one or more combined openings <NUM> in the portion <NUM>. Once the article <NUM> is formed, the one or more combined opening <NUM> form the one or more apertures <NUM> fluidly connecting the inner region <NUM> to the outer region <NUM> of the portion <NUM>.

In one embodiment, the additive method <NUM> includes the DMLM process. In another embodiment, the DMLM process includes providing the metal alloy powder <NUM> and depositing the metal alloy powder <NUM> to form an initial powder layer. The initial powder layer has the preselected thickness <NUM> and the preselected shape including the at least one first opening <NUM>. In a further embodiment, the DMLM process includes providing a focused energy source <NUM>, and directing the focused energy source <NUM> at the initial powder layer to melt the metal alloy powder <NUM> and transform the initial powder layer to the portion <NUM> of the article <NUM> and/or conduits <NUM>. Suitable focused energy sources include, but are not limited to, laser device, an electron beam device, or a combination thereof.

Next, the DMLM process includes sequentially depositing additional metal alloy powder <NUM> over the portion <NUM> of the article <NUM> and/or conduits <NUM> to form the additional layer <NUM> having the second preselected thickness <NUM> and the second preselected shape including the at least one second opening <NUM> corresponding to the at least one first opening <NUM> in the initial powder layer <NUM>. After depositing the additional layer <NUM> of the metal alloy powder <NUM>, the DMLM process includes melting the additional layer <NUM> with the focused energy source <NUM> to increase the combined thickness <NUM> and form the at least one combined opening <NUM> having a predetermined profile.

The steps of sequentially depositing the additional layer <NUM> of the metal alloy powder <NUM> and melting the additional layer <NUM> may then be repeated to form the net or near-net shape article <NUM> and/or conduits <NUM>. For example, the steps may be repeated until the article <NUM> having the predetermined thickness, the predetermined shape, and the one or more apertures <NUM> having any suitable geometry is obtained. Additionally, the steps may be repeated to form the one or more conduits <NUM> directly over at least one of the one or more apertures <NUM>. In one embodiment, the one or more conduits <NUM> include support members configured to provide support during the additive method <NUM>. The support members may form a portion of the article <NUM>, or may be removed after formation to form the article <NUM> devoid or substantially devoid of support members.

As discussed in detail above, and as illustrated in <FIG>, the conduits <NUM> are normal and/or angled relative to the body portion <NUM>, and may be formed to maintain, extend, and/or modify the flow of fluid from the apertures <NUM>. For example, in a non-claimed embodiment, as shown in <FIG>, the conduit <NUM> extends the orientation and cross-sectional geometry of the aperture <NUM>. In another non-claimed example, as illustrated in <FIG>, the conduit <NUM> is angled relative to the body portion <NUM>, the angle of the conduit <NUM> maintaining the cross-section geometry while modifying the orientation of the aperture <NUM>. The angle may also be selected to provide support during the additive manufacturing of the article <NUM>. Suitable angles for modifying the orientation of the aperture <NUM> and/or providing support during the additive manufacturing include, but are not limited, to between <NUM>° and <NUM>°, between <NUM>° and <NUM>°, between <NUM>° and <NUM>°, between <NUM>° and <NUM>°, between <NUM>° and <NUM>°, between <NUM>° and <NUM>°, between <NUM>° and <NUM>°, between <NUM>° and <NUM>°, about <NUM>°, about <NUM>°, about <NUM>°, or any combination, sub-combination, range, or sub-range thereof. As illustrated in <FIG>, the cross-sectional geometry of the conduit <NUM> differs from that of the aperture <NUM>. According to the invention, the cross-sectional geometry of the interior surface of the conduit is a star-shaped cross-sectional geometry, that extends the non-round geometry of the aperture.

In one embodiment, the additive method <NUM> includes forming the orifice feature <NUM> on the conduit <NUM>. In another embodiment, the conduit <NUM> and the orifice feature <NUM> are formed during the forming of the article <NUM>. Additionally or alternatively, the conduit <NUM> and/or the orifice feature <NUM> may be formed separately from and/or after the forming of the article <NUM>. For example, the conduit <NUM> and/or the orifice feature <NUM> may be formed directly on a previously formed article <NUM> using the additive method <NUM>, or the conduit <NUM> and/or the orifice feature <NUM> may be formed separate from the article <NUM> then attached to the article <NUM>. Forming the conduit <NUM> and/or the orifice feature <NUM> separate from the article <NUM> may include either the additive method <NUM> or a non-additive method such as machining and/or casting.

Claim 1:
An impingement sleeve (<NUM>) for insertion within a turbine nozzle (<NUM>), said impingement sleeve comprising:
a body portion (<NUM>) separating an inner region (<NUM>) and an outer region (<NUM>);
an aperture (<NUM>) in the body portion (<NUM>), the aperture (<NUM>) fluidly connecting the inner region (<NUM>) to the outer region (<NUM>); and
a conduit (<NUM>) extending from an outer surface (<NUM>) of the body portion (<NUM>) at the aperture (<NUM>) and being arranged and disposed to controllably direct fluid from the inner region (<NUM>) to the outer region (<NUM>),
characterised in that the cross-sectional geometry of an interior surface of the conduit (<NUM>) is a star shaped cross-sectional geometry, that extends a non-round geometry of the aperture (<NUM>).