Session: 13-01 Heat Transfer in Turbines

Submission Number: 176031

Enhanced Internal Cooling Performance Through TPMS Lattice Designs Using Advanced 3D-Printing Process of a Nickel Superalloy 

Today, internal cooling designs in gas turbine components are no longer limited by traditional manufacturing methods. Indeed, additive manufacturing (AM) makes it possible to create more effective internal cooling designs than ever. This work focuses on the design, manufacturing, and performance evaluation of using triply periodic minimal surface (TPMS) lattice geometries, such as Gyroid, Schwarz-P, and Diamond topologies, as enhanced internal cooling features.

A series of test coupons were additively built (LPBF) in collaboration with EOS, a leading provider of AM solutions, to assess printability of such complex cooling lattices. Geometrical feature resolution, surface roughness, and porosity were evaluated through material lab analyses to identify suitable manufacturable TPMS designs.

In addition, detailed conjugate heat transfer analyses were conducted at engine-relevant boundary conditions for specific TPMS designs in order to quantify the overall cooling efficiency. Results show that cooling passages using such geometry features can exhibit up to 50% improvement in overall cooling efficiency compared to traditional designs with the same amount cooling air mass flow.

This paper also addresses some practical challenges of implementing TPMS architectures with super alloys, including laser parameter optimization, printability, down-skin roughness and powder removal. The demonstrated manufacturability supported by EOS (see other submitted paper: Processing CM247LC for turbomachinery applications using ring-shaped beams in laser powder bed fusion) and the predicted cooling performance of these designs highlight the potential of TPMS lattices as the next-generation cooling solution for high-temperature turbine components.

Presenting Author: Gregory Vogel Power Systems Mfg., LLC

Presenting Author Biography: Dr. Gregory Vogel, Senior Technology Programs Manager at PSM in Jupiter, Florida, brings over 23 years of experience in the industrial gas turbine business.
He began his career in 2002 with Alstom in Switzerland and later led aero and cooling design efforts in Florida. Since joining PSM in 2010, Greg has led upgrades for GE, Siemens, and Mitsubishi F-class turbines. He drives innovation in additive manufacturing, fuel flexibility, and data analytics. He holds numerous patents and a PhD in turbine cooling from the Swiss Federal Institute of Technology in Lausanne.

Authors:

Gregory Vogel Power Systems Mfg., LLC
Ryan Edelson Power Systems Mfg., LLC
Nathan O'nora Power Systems Mfg., LLC
Tobias Novotny EOS GmbH Electro Optical Systems