ADDITIVELY MANUFACTURED INTERMEDIATE CHANNEL FOR ARRANGING BETWEEN A LOW-PRESSURE COMPRESSOR AND A HIGH-PRESSURE COMPRESSOR, AND CORRESPONDING MANUFACTURING METHOD

Abstract

An intermediate duct (10) for disposition between an outlet of a low-pressure compressor and an inlet of a high-pressure compressor of a turbomachine, in particular of an aircraft engine is provided, the intermediate duct including an outer wall (2) and an inner wall (3) between which are disposed an optional exit stator ring (4) and at least one strut (12) extending radially with respect to a central axis of the intermediate duct (10). The intermediate duct (10) is at least partially manufactured by additive manufacturing. A method for manufacturing such an intermediate duct (10), and a turbomachine having such an intermediate duct (10) are also provided.

Claims

1-15. (canceled)

16. An intermediate duct for disposition between an outlet of a low-pressure compressor and an inlet of a high-pressure compressor of a turbomachine, the intermediate duct comprising: an outer wall; an inner wall; at least strut disposed between the outer wall and the inner wall and extending radially with respect to a central axis of the intermediate duct; the intermediate duct at least partially manufactured by additive manufacturing.

17. The intermediate duct as recited in claim 16 wherein the intermediate duct is composed of at least two connected segments.

18. The intermediate duct as recited in claim 16 wherein the outer wall or the inner wall or the at least one strut or an exit stator ring disposed between the outer wall and the inner wall include at least one cavity.

19. The intermediate duct as recited in claim 18 wherein the at least one cavity is configured as an open cavity or the at least one cavity is round or oval in cross section or at least two cross sections of the at least one cavity are staggered relative to each other or the at least one cavity has at least one constriction or the cavity is supported by at least one supporting strut.

20. The intermediate duct as recited in claim 18 wherein the at least one cavity is configured a closed cavity or the at least one cavity is round or oval in cross section or at least two cross sections of the at least one cavity are staggered relative to each other or the at least one cavity has at least one constriction or the cavity is supported by at least one supporting strut.

21. The intermediate duct as recited in claim 18 wherein the outer wall or the inner wall or the at least one strut or an exit stator ring disposed between the outer wall and the inner wall include at least one cavity or at least one supporting strut supporting the cavity have a bionic design.

22. The intermediate duct as recited in claim 16 wherein the at least one strut includes a cavity forming a channel having an inlet port and an outlet port and allowing an operating fluid to be passed therethrough through the intermediate duct.

23. The intermediate duct as recited in claim 22 wherein a fill factor of the at least one strut is between 15% and 95%.

24. The intermediate duct as recited in claim 23 wherein the fill factor is between 50% and 90%.

25. The intermediate duct as recited in claim 16 wherein a thickness ratio of to maximum thickness to an axial length of the at least one strut is between 15% and 45%.

26. The intermediate duct as recited in claim 16 wherein the at least one strut has an out-of-plane curvature in the circumferential direction.

27. The intermediate duct as recited in claim 26 wherein a radial shape of a trailing edge of the at least one strut has a deviation of no more than ±7° in the circumferential direction, considered with respect to a round angle.

28. The intermediate duct as recited in claim 26 wherein a radial shape of the at least one strut lies within a first boundary contour and a second boundary contour, at least in the region of a trailing edge, the first boundary contour being defined by the formula (I):
y=71.14x.sup.5−179.74x.sup.4+134.76x.sup.3−2.6539x.sup.2−27.72x+5.5815   (I) and the second boundary contour is defined by formula (II):
y=71.14x.sup.5−179.74x.sup.4+134.76x.sup.3−2.6539x.sup.2−27.72x+1.5815   (II), where x denotes the percentage of the radial height of the strut from the inner wall of the intermediate duct in the region of its trailing edge, and y denotes the deviation, in degrees, in the circumferential direction from a hypothetical linear trailing edge contour having a constant radial shape at 0°.

29. The intermediate duct as recited in claim 16 further comprising an exit stator ring extending radially with respect to a central axis of the intermediate duct.

30. The intermediate duct as recited in claim 16 wherein the intermediate duct is made from a titanium alloy or from a nickel-based alloy.

31. The intermediate duct as recited in claim 30 wherein the intermediate duct is made from titanium 6246 or from IN100.

32. A method for manufacturing an intermediate duct to be disposed between an outlet of a low-pressure compressor and an inlet of a high-pressure compressor of a turbomachine, the intermediate duct including an outer wall and an inner wall between which is disposed an at least one strut extending radially with respect to a central axis of the intermediate duct, the method comprising: manufacturing at least part of the intermediate duct by additive manufacturing.

33. The method as recited in claim 32 wherein the outer wall or the inner wall or the at least one strut or an exit stator ring disposed between the outer wall and the inner wall include at least one cavity or at least one supporting strut supporting the cavity are manufactured with at least one cavity or with a bionic design.

34. A turbomachine comprising: at least a low-pressure compressor and a high-pressure compressor; an intermediate duct disposed between an outlet of the low-pressure compressor and an inlet of the high-pressure compressor, the intermediate duct being as recited in claim 1.

35. An aircraft engine comprising the turbomachine as recited in claim 34.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0023] Other features of the invention will become apparent from the claims, the figures, and the detailed description. The features and feature combinations mentioned above in the description as well as the features and feature combinations mentioned below in the description of the figures and/or shown in isolation in the figures are usable not only in the respectively specified combination, but also in other combinations without departing from the scope of the invention. Thus, embodiments of the invention which are not explicitly shown in the figures or described, but derive from and can be produced by separate feature combinations from the explained embodiments, are also considered to be included and disclosed herein. In addition, embodiments and combinations of features that therefore do not have all of the features of an originally formulated independent claim are also considered to be disclosed herein. Moreover, embodiments and combinations of features that go beyond or differ from the combinations of features set forth in the back-references of the claims should be regarded as having been disclosed, in particular by the embodiments set forth above.

[0024] In the drawing,

[0025] FIG. 1 is a perspective detail view of an intermediate duct known from the prior art;

[0026] FIG. 2 is a perspective detail view of an intermediate duct according to the invention;

[0027] FIG. 3 is a perspective plan view of an inner wall and a strut of the intermediate duct;

[0028] FIG. 4 is a perspective plan view of an outer wall and the strut of the intermediate duct;

[0029] FIG. 5 is a perspective view of two half-shells forming the intermediate duct;

[0030] FIG. 6 is a schematic axial sectional view of the intermediate duct;

[0031] FIG. 7 is a schematic radial sectional view of the intermediate duct in a radial section along line A-A in FIG. 6;

[0032] FIG. 8 is a schematic cross section of a strut of the intermediate duct;

[0033] FIG. 9 is a schematic axial sectional view of the intermediate duct according to another exemplary embodiment;

[0034] FIG. 10 is a diagram illustrating a radial contour shape in the region of a trailing edge of the strut;

[0035] FIG. 11 is a schematic cross section of another exemplary embodiment of the strut;

[0036] FIG. 12 is a schematic axial sectional view of the intermediate duct according to another exemplary embodiment; and

[0037] FIG. 13 is a schematic cross section of another exemplary embodiment of the strut.

DETAILED DESCRIPTION

[0038] FIG. 1 shows, in perspective view, a detail of an intermediate duct 1 known from the prior art. The basic geometry of the radially symmetric intermediate duct 1 (inter-compressor duct (ICD)) is derived from the requirement of redirecting the flow through intermediate duct 1 to a significantly smaller radius, while at the same time keeping aerodynamic losses to a minimum and ensuring highest possible uniformity of the flow at the outlet of intermediate duct 1. Intermediate duct 1 (ICD) includes, in addition to an outer wall 2 (see FIG. 4) and an inner wall 3, an aerodynamically profiled exit stator ring 4 (outlet guide vane (OGV) assembly) disposed at the inlet of intermediate duct 1 and having a large number of vanes. The number of vanes is generally at least approximately equal to the number of blades of a last rotor stage of an upstream low-pressure compressor (LPC). Disposed downstream of exit stator ring 4 are a plurality of circumferentially spaced-apart struts 5 (also called supporting ribs), which substantially connect outer wall 2 and inner wall 3 together and support them structurally and mechanically. The ratio of the vanes of exit stator ring 4 to struts 5 may generally be varied between about 8:1 and about 16:1, and may be, for example, 12:1. The manufacture of intermediate duct 1 (ICD) requires the provision of complex components; i.e., an OGV assembly 4 including rings and guide vanes, as well as one (or more) component(s) for each of the outer and inner walls 2, 3 of intermediate duct 1, as well as the individual struts 5 connecting outer and inner walls 2, 3. The components of intermediate duct 1 are formed by precision casting as well as by turning and milling processes and, therefore, have relatively simple geometries, including closed shapes of solid material. Due to the steepness of intermediate duct 1, it is (economically) not or hardly possible to manufacture more complex geometries using conventional casting, turning and milling processes.

[0039] FIG. 2 shows a perspective detail of an inventive intermediate duct 10 that is additively manufactured using a laser melting process. Additive manufacturing of intermediate duct 10 (ICD) avoids the above-mentioned disadvantages and is limited essentially by component size limitations imposed by the production machine used. It can be seen that the exemplarily shown strut 12 has a complex, curved structure (“S-curvature”), which, depending on its configuration, may perform an aerodynamic function to impart a swirl to the flow or to straighten the flow. In some embodiments of intermediate duct 10, it is therefore possible to completely dispense with an exit stator ring 4. This allows a further reduction in the length of intermediate duct 10, thus allowing for further weight and space savings. Since the essential function of intermediate duct 10, in addition to geometrically connecting the low-pressure compressor and the high-pressure compressor, is to redirect the flow with as little loss as possible, the load-bearing capability of the component is limited. Therefore, intermediate duct 10 may be manufactured in the form of a bionic hollow structure.

[0040] FIG. 3 shows a perspective plan view of inner wall 3 and strut 12 of intermediate duct 10, while FIG. 4 shows a perspective plan view of outer wall 2 and strut 12 of intermediate duct 10. It can be seen that, as an alternative or in addition to the complex geometry of the strut 12, complex three-dimensional structures of outer and/or inner walls 2, 3 can also be fabricated when using additive manufacturing. By way of example, relative elevations located downstream are indicated by red elevation contour line areas, while blue elevation contour line areas indicate relative depressions located upstream. In the aft 30% of the chord length of strut 12, the following contouring parameters should be provided (for each strut section) in the design for aerodynamic loss reduction: [0041] Inner wall 3:

[0042] Variation of the inner wall radii in the range with a protrusion of up to about 5% into the duct and a maximum height variation near the trailing edge HK; local, weakly varying annular outward relaxation or deformation at the duct inlet. [0043] Outer wall 2:

[0044] Variation of the outer wall radii in the range of about 2-3% with two outward contour features, whereas a weakly varying annular constriction is formed at the duct inlet. Other geometries are also conceivable.

[0045] FIG. 5 shows a perspective view of two half-shells 10a, 10b, of which intermediate duct 10 is composed; i.e., from which it is assembled. In this view, there can be seen the circumferentially distributed struts 12 and the flow passages of intermediate duct 10 located therebetween. The rear side (not visible in FIG. 5) is mounted to an outlet of a low-pressure compressor (not shown) of an aircraft engine, while a front side is mounted to an inlet of a high-pressure compressor (not shown).

[0046] FIG. 6 shows a schematic axial sectional view of intermediate duct 10 and is described below in conjunction with FIG. 7 and FIG. 8. FIG. 7 shows a schematic radial sectional view of intermediate duct 10 in a radial section along line A-A in FIG. 6, while FIG. 8 shows a schematic cross section of strut 12 of intermediate duct 10 at about 65% radial depth. It can be seen that the working fluid entering intermediate duct 10 from the low-pressure compressor, as indicated by arrow VIa, passes through optional exit stator ring 4, is redirected radially inwardly, flows past struts 12 and further toward the high-pressure compressor, as indicated by arrow VIb. As can be seen in FIG. 7, outer wall 2 and strut 12 have a bionic design with numerous cavities 14. The same holds true for inner wall 3 (not shown). In region VIIa, the thicknesses of the walls bounding the gas path can be minimized while preserving the hollow structures and in such a way that the gas path loads (impulse, pressure, wall friction) are borne and the material characteristics are optimally utilized. In region VIIb, strut 12 can be optimally designed with a minimal wall thickness and possibly local reinforcements (leading and trailing edges). Furthermore, channels 16 for supply lines (oil lines, etc.) may be provided. In region VIIc, if necessary, axial loads can be dissipated via outer wall 2 directly along rib structure VIIa, or loads can be introduced in a weight-optimized manner from struts 12 via locally reinforced hollow structures in the connection from strut 12 into outer wall 2. In FIG. 8, it can be seen that strut 12 includes two cavities 14, which generally have an oval shape and a constriction 18 approximately in the middle of each. In this embodiment, the fill factor of the at least one strut is about 18%.

[0047] FIG. 9 shows a schematic axial sectional view of intermediate duct 10 according to another exemplary embodiment. It can be seen that, due to the curved, aerodynamically optimized design of strut(s) 12, it is possible to completely dispense with an exit stator ring 4.

[0048] FIG. 10 shows a diagram of the radial contour shape K in the region of a trailing edge HK of the strut 12 depicted in FIG. 9, looking in the direction IX indicated in FIG. 9. The radial extent of strut 12 from inner wall 3 (x=0) to outer wall 2 (x=1) is plotted on the x-axis in steps of 10%, while the deviation in angular degrees from a hypothetical, linear trailing edge (y=0°) is plotted on the y-axis. Also shown are a first boundary contour K1 and a second boundary contour K2, which define a range within which contour K of strut 12 can be freely varied. First boundary contour K1 is approximately defined by formula (I):

y=71.14x.sup.5−179.74x.sup.4+134.76x.sup.3−2.6539x.sup.2−27.72x+5.5815   (I)

and the second boundary contour is defined by formula (II):

y=71.14x.sup.5−179.74x.sup.4+134.76x.sup.3−2.6539x.sup.2−27.72x+1.5815   (II),

The exemplarily shown contour K is approximately defined by formula (III):

y=71.14x.sup.5−179.74x.sup.4+134.76x.sup.3−2.6539x.sup.2−27.72x+3.5815   (III)

[0049] FIG. 11 shows a schematic cross section of another exemplary embodiment of strut 12 in a section along line B-B in FIG. 9. It can be seen that a fill factor of strut 12 can be varied between 84% (solid-line cavity 14) and 64% (dashed-line cavity 14). Cavity 14 has supporting struts 13 like a human bone. In the present case, thickness ratio D/L can be varied between 17% and 35%. Cavity 14 may be configured in the manner of a through-bore as a channel 16 for passage of oil, air, or other operating fluids therethrough, and may have radially inner and outer ports.

[0050] FIG. 12 shows a schematic axial sectional view of intermediate duct 10 according to another exemplary embodiment; while FIG. 13 shows a schematic cross section of another exemplary embodiment of strut 12 in a section along line C-C in FIG. 12. It can be seen that strut 12 has a cavity 14 configured as a channel 16 extending therethrough. At least two cross sections of channel 16, such as, for example the two cross-sections at the inlet into and at the outlet from strut 12, are staggered relative to each other, so that channel 16 cannot be formed using a drill, for example. In the region of inner wall 3, channel 16 opens into an outlet area 20 for supplying oil, air, or the like, to a hub (not shown) of the turbomachine. In this embodiment, too, thickness ratio D/L is between 17% and 35%.

[0051] The parameter values given in the documents for defining process and measurement conditions for characterizing specific properties of the subject matter of the invention are also to be considered as within the scope of the invention, even in the context of deviations, e.g., due to measurement errors, system errors, DIN tolerances, and the like.

LIST OF REFERENCE NUMERALS

[0052] 1 intermediate duct [0053] 2 outer wall [0054] 3 inner wall [0055] 4 exit stator ring [0056] 5 strut [0057] 10 intermediate duct [0058] 10a half-shell [0059] 10b half-shell [0060] 12 strut [0061] 13 supporting strut [0062] 14 cavity [0063] 16 channel [0064] 18 constrictions [0065] 20 outlet area [0066] D thickness [0067] L length [0068] HK trailing edge [0069] K1 first boundary contour [0070] K2 second boundary contour