Casting plug with flow control features

Abstract

A casting plug for a vane of a gas turbine engine includes a plug body a flow control feature and a support that extends between the plug body and the flow control feature.

Claims

1. A casting plug for a component of gas turbine engine, comprising: a plug body that seals a core support aperture of a component; a flow control feature that extends into a flow path within an airfoil of the component; and a support that extends between the plug body and the flow control feature, the support transverse to the flow control feature to operates as a flow splitter.

2. The casting plug as recited in claim 1, wherein the plug body is received within a platform of a vane.

3. The casting plug as recited in claim 2, wherein the platform is at least one of an outer platform and an inner platform, the airfoil between the outer platform and the inner platform.

4. The casting plug as recited in claim 1, wherein the flow control feature is located between two flow paths within the airfoil.

5. The casting plug as recited in claim 4, wherein the flow control feature comprises a turning vane.

6. The casting plug as recited in claim 4, wherein the flow control feature forms an airfoil shape.

7. The casting plug as recited in claim 4, wherein the flow control feature forms an arcuate shape.

8. The casting plug as recited in claim 1, wherein the plug body forms a portion of an outer periphery of the flow path.

9. The casting plug as recited in claim 1, wherein the casting plug is additively manufactured and the component is cast.

10. The casting plug as recited in claim 1, wherein the flow control feature extends into the flow path within the airfoil of the component to be adjacent to an end of a rib within the airfoil.

11. A vane for a gas turbine engine, comprising: an outer platform; an inner platform; a vane airfoil between the outer platform and the inner platform with a plurality of flow passages within the vane airfoil; and a casting plug received into a core support aperture in one of the outer platform and the inner platform of the vane, the casting plug comprising a flow control feature that extends into a flow path within the vane airfoil from a plug body by a support transverse to the flow control feature at least partially define at least one of the plurality of flow passages within the vane airfoil.

12. The vane as recited in claim 11, wherein at least two of the plurality of flow passages within the airfoil are separated by a rib.

13. The vane as recited in claim 12, wherein the flow control feature is adjacent to an end of the rib.

14. The vane as recited in claim 13, wherein the flow control feature is arcuate.

15. The vane as recited in claim 13, further comprising a support that extends between a plug body and the flow control feature, wherein the support is transverse to the flow control feature.

16. The vane as recited in claim 11, wherein the casting plug is additively manufactured and the component is cast.

17. The vane as recited in claim 11, wherein the flow control feature extends into the flow path within the airfoil of the component to be adjacent to an end of a rib within the airfoil.

18. A method for manufacturing a component for a gas turbine engine, the method comprising: welding a casting plug into a core support aperture of a vane, the casting plug comprising a flow control feature that extends into a flow path within a vane airfoil to at least partially define a turn region of at least one of a plurality of flow passages within the vane airfoil.

19. The method as recited in claim 18, wherein a thickness of the support controls the cooling flow through the at least one of the plurality of flow passages within the component.

20. The method as recited in claim 18, further comprising additively manufacturing the casting plug and casting the component.

21. The method as recited in claim 18, wherein flow control feature extends into the flow path within the vane airfoil adjacent to an end of a rib within the vane airfoil.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) Various features will become apparent to those skilled in the art from the following detailed description of the disclosed non-limiting embodiment. The drawings that accompany the detailed description can be briefly described as follows:

(2) FIG. 1 is a partial exploded view of a vane ring of one turbine stage within a high pressure turbine section of the gas turbine engine, the vane ring formed from a multiple of vane segments.

(3) FIG. 2 is an expanded view of one vane segment.

(4) FIG. 3 is a sectional view of the turbine vane illustrating a casting plug according to one disclosed non-limiting embodiment.

(5) FIG. 4 is a sectional view of the turbine vane illustrating a RELATED ART casting plug.

(6) FIG. 5 is a perspective view of the casting plug.

(7) FIG. 6 is a front view of the casting plug.

(8) FIG. 7 is a schematic view of cooling flow modified by the casting plug.

DETAILED DESCRIPTION

(9) FIG. 1 schematically illustrates a vane 20 for a gas turbine engine. The vane 20 includes an outer platform 22 and an inner platform 24 radially spaced apart from each other by a vane airfoil 28. The arcuate outer platform 22 may form a portion of an outer core engine structure and the arcuate inner platform 24 may form a portion of an inner core engine structure to at least partially define an annular turbine nozzle core airflow flow path.

(10) The adjacent vanes 20 may be sealed therebetween, with, for example only, spline seals. The substantial aerodynamic and thermal loads are accommodated by the plurality of circumferentially adjoining vane segments which collectively form a full, annular ring 30 about the centerline axis A of the engine. It should be appreciated the any number of vane airfoils 28 may be included in each vane segment. For purposes of this description, the vane 20 will be described as forming a sole airfoil of a segment. Although a portion of a turbine section is shown by way of example in the disclosed embodiment, it should be appreciated that the concepts described herein are not limited to use with high pressure turbines as the teachings may be applied to other components in other engine sections such as blades and vanes within the low pressure turbines, power turbines, intermediate pressure turbines as well as other cooled airfoil structures with any number of stages.

(11) With reference to FIG. 2, each airfoil 28 is defined by an outer airfoil wall surface 32 between a leading edge 34 and a trailing edge 36. The outer airfoil wall surface 32 defines a generally concave shaped portion forming a pressure side 38 and a generally convex shaped portion forming a suction side 40 to form a passage array 42 therein.

(12) In this exemplary embodiment, the passage array 42 has a plurality of flow passages 44, for example, a leading edge passage 46, a trailing edge passage 48 and an intermediate passage 50 (FIG. 3). A multiple of structural ribs 52 are integrally cast between the pressure side 38 and the suction side 40 for supporting the outer airfoil wall surface 32 and to form the passage array 42. The passage array 42 is in flow communication with an airflow source such as a bleed air from a compressor section for impingement and/or convection cooling of the vane 20. The post impingement coolant flows through the passages to outlets 54 such as those adjacent the trailing edge 36.

(13) A casting plug 70 is welded into the vane airfoil 28 to close an outer diameter core support aperture 80. The casting plug 70 replaces a conventional casting plug and thereby permits the elimination of an outer diameter bend turning rib R (FIG. 4; RELATED ART) from the casting by including the turning feature into the casting plug 70.

(14) With reference to FIG. 5, the casting plug 70 includes a plug body 72, a flow control feature 74 and a support 76 that extends between the plug body 72 and the flow control feature 74. The casting plug 70 may be additively manufactured or otherwise formed into any desired geometry to minimize or eliminate flow dead zones such that the cooling flow is fully developed at the turn region. The plug body 72 is readily formed to seal the outer diameter core support aperture 80.

(15) The support 76 may be transverse (FIG. 6) to the flow control feature 74. The support 76, in one embodiment, is an extension that locates the flow control feature 74 adjacent to an end 56 (FIG. 3) of the rib 52. The support 76 operates as a flow splitter and the thickness of the support 76 may also be readily configured to control and meter the cooling flow without additional casting changes to the vane airfoil 28.

(16) The flow control feature 74 may be arcuate, airfoil shaped, or of other geometries to facilitate flow between one or more of the passages in the passage array 42. The flow control feature 74 may be utilized to minimize flow turbulence within the passage array 42 (FIG. 6).

(17) The casting plug 70 eliminates casting problems associated with cast turning ribs. The design may be more castable, easier to leach core and less prone to break. In addition, it will prevent turning rib solidification and porosity issues during the casting process. This reduces scrap rate and manufacturing cost. The casting plug 70 also facilitates full development of the flow for optimum cooling effectiveness at the turn region. The casting plug 70 may also control and meter the cooling flow without the need for additional casting changes by controlling the thickness of the support 76. That is, a different casting plug 70 can be inserted into a common vane airfoil geometry so that the cooling airflow therein may be particularly tailored by replacement of the casting plug 70.

(18) The foregoing description is exemplary rather than defined by the limitations within. Various non-limiting embodiments are disclosed herein, however, one of ordinary skill in the art would recognize that various modifications and variations in light of the above teachings will fall within the scope of the appended claims. It is therefore to be appreciated that within the scope of the appended claims, the disclosure may be practiced other than as specifically described. For that reason the appended claims should be studied to determine true scope and content.