Airfoil with tunable cooling configuration

Abstract

Airfoils, additively manufactured airfoils, and methods of manufacturing airfoils are provided. For example, an airfoil comprises opposite pressure and suction sides that extend axially from a leading edge to a trailing edge and radially spaced apart inner and outer ends. The airfoil also comprises an outer wall defining the pressure and suction sides and leading and trailing edges. A rib extends within the airfoil from the pressure side to the suction side of the outer wall and radially from the inner to the outer end. The airfoil further comprises a first pre-impingement chamber surrounded by a first post-impingement chamber and a first dividing wall segment separating the first pre-impingement and first post-impingement chambers and having a plurality of cooling holes defined therein. The outer wall, rib, and first dividing wall segment are integrally formed as a single monolithic component.

1 .- 20 . (canceled) 
     
     
         21 . An airfoil, comprising:
 a concave pressure side opposite a convex suction side and an inner end radially spaced apart from an outer end, the pressure side and the suction side extending axially from a leading edge to a trailing edge;   an outer wall defining the pressure side, suction side, leading edge, and trailing edge;   a rib extending linearly within the airfoil from the pressure side of the outer wall to the suction side of the outer wall, the rib further extending radially from the inner end to the outer end;   a pre-impingement chamber;   a post-impingement chamber surrounding the pre-impingement chamber; and   a dividing wall separating the pre-impingement chamber from the post-impingement chamber.   
     
     
         22 . The airfoil of  claim 21 , wherein the outer wall, the rib, and the dividing wall are integrally formed as a single monolithic component. 
     
     
         23 . The airfoil of  claim 21 , further comprising:
 a plurality of cooling holes defined in the dividing wall, the plurality of cooling holes including a first plurality of cooling holes defined at a first radial location along the dividing wall, a second plurality of cooling holes defined at a second radial location along the dividing wall, and a third plurality of cooling holes defined at a third radial location along the dividing wall.   
     
     
         24 . The airfoil of  claim 23 , wherein the first plurality of cooling holes are defined at different axial locations than any of the second plurality of cooling holes and any of the third plurality of cooling holes, wherein the second plurality of cooling holes are defined at different axial locations than any of the first plurality of cooling holes and any of the third plurality of cooling holes, and wherein the third plurality of cooling holes are defined at different axial locations than any of the first plurality of cooling holes and any of the second plurality of cooling holes 
     
     
         25 . The airfoil of  claim 21 , wherein the pre-impingement chamber and the post-impingement chamber are defined forward of the rib. 
     
     
         26 . The airfoil of  claim 21 , wherein the pre-impingement chamber and the post-impingement chamber are defined aft of the rib. 
     
     
         27 . The airfoil of  claim 21 , wherein the dividing wall comprises a forward dividing wall segment defining a forward pre-impingement chamber and a forward post-impingement chamber and an aft dividing wall segment defining an aft pre-impingement chamber and an aft post-impingement chamber, and wherein each of the forward dividing wall segment and the aft dividing wall segment are integrally formed with the rib. 
     
     
         28 . The airfoil of  claim 21 , wherein the outer wall defines a cavity within the airfoil between the pressure side, the suction side, the leading edge, and the trailing edge, wherein the rib separates the cavity into a forward cavity and an aft cavity, and wherein the dividing wall wraps around the forward cavity adjacent the pressure side, the suction side, and the leading edge to define the pre-impingement chamber and the post-impingement chamber. 
     
     
         29 . The airfoil of  claim 21 , further comprising:
 an impingement insert separately formed from the airfoil,   wherein the impingement insert is disposed in the aft cavity.   
     
     
         30 . The airfoil of  claim 21 , wherein the outer wall defines a cavity within the airfoil between the pressure side, the suction side, the leading edge, and the trailing edge, wherein the rib separates the cavity into a forward cavity and an aft cavity, and wherein the dividing wall wraps around the aft cavity adjacent the pressure side, the suction side, and the trailing edge to define the pre-impingement chamber and the post-impingement chamber. 
     
     
         31 . The airfoil of  claim 21 , further comprising:
 an impingement insert separately formed from the airfoil,   wherein the impingement insert is disposed in the forward cavity.   
     
     
         32 . The airfoil of  claim 21 , wherein the outer wall defines a cavity within the airfoil between the pressure side, the suction side, the leading edge, and the trailing edge, wherein the rib separates the cavity into a forward cavity and an aft cavity, and wherein the dividing wall comprises a first dividing wall segment and a second dividing wall segment, the first dividing wall segment separately formed from the second dividing wall segment, each of the first dividing wall segment and the second dividing wall segment integrally formed with the rib. 
     
     
         33 . The airfoil of  claim 21 , wherein the rib is a first rib, and further comprising:
 a second rib extending linearly within the airfoil from the pressure side of the outer wall to the suction side of the outer wall and extending radially from the inner end to the outer end,   wherein the second rib is defined aft of the first rib, and   wherein the outer wall, the first rib, the second rib, and the dividing wall are integrally formed as a single monolithic component.   
     
     
         34 . An airfoil, comprising:
 a concave pressure side opposite a convex suction side and an inner end radially spaced apart from an outer end, the pressure side and the suction side extending axially from a leading edge to a trailing edge;   an outer wall defining the pressure side, the suction side, the leading edge, and the trailing edge, the outer wall defining a cavity within the airfoil between the pressure side, the suction side, the leading edge, and the trailing edge;   a rib extending within the airfoil from the pressure side of the outer wall to the suction side of the outer wall, the rib further extending radially from the inner end to the outer end, the rib separating the cavity into a forward cavity and an aft cavity; and   an impingement baffle integrally formed with the rib, the impingement baffle disposed in one of the forward cavity and the aft cavity.   
     
     
         35 . The airfoil of  claim 34 , wherein the rib extends linearly from the pressure side to the suction side. 
     
     
         36 . The airfoil of  claim 34 , wherein the rib defines a rib crossover hole therein, and wherein the impingement baffle defines a plurality of cooling holes therein. 
     
     
         37 . The airfoil of  claim 36 , wherein the rib and the impingement baffle define at least three chambers arranged in series, the rib crossover hole and the plurality of cooling holes fluidly connecting the three chambers. 
     
     
         38 . The airfoil of  claim 34 , further comprising:
 an impingement insert separately formed from the airfoil,   wherein the impingement insert is disposed in the other of the forward cavity and the aft cavity.   
     
     
         39 . The airfoil of  claim 36 , wherein the outer wall, the rib, and the impingement baffle are integrally formed as a single monolithic component. 
     
     
         40 . An airfoil, comprising:
 a concave pressure side opposite a convex suction side and an inner end radially spaced apart from an outer end, the pressure side and the suction side extending axially from a leading edge to a trailing edge;   an outer wall defining the pressure side, the suction side, the leading edge, and the trailing edge, the outer wall defining a cavity within the airfoil between the pressure side, the suction side, the leading edge, and the trailing edge;   a rib extending within the airfoil from the pressure side of the outer wall to the suction side of the outer wall, the rib separating the cavity into a forward cavity and an aft cavity; and   an impingement baffle integrally formed with the rib, the impingement baffle extending from the rib into one of the forward cavity and the aft cavity.