Fatigue resistant blade outer air seal
A blade outer air seal segment including a radially outward surface, a radially inward surface oriented away from the radially outward surface, and a cooling channel located between the radially outward surface and the radially inward surface. The blade outer air seal segment also including a stress-relief boss extending into the cooling channel and an inlet orifice fluidly coupled to the cooling channel through the stress-relief boss. The blade outer air seal segment further including a stress-relief recess. The stress-relief boss being located within the stress relief recess.
1. A method of forming a blade outer air seal segment, comprising:
depositing a blade outer air seal material around a core, the core being configured to define features of the blade outer air seal segment, the blade outer seal segment having:
a radially outward surface;
a radially inward surface oriented away from the radially outward surface, a radially outward wall interposed between the radially outward surface and the radially inward surface;
a cooling channel located between the radially outward surface and the radially inward surface;
a stress-relief boss extending into the cooling channel;
an inlet orifice fluidly coupled to the cooling channel through the stress-relief boss;
a stress-relief recess, the stress-relief boss being located within the stress-relief recess;
wherein the cooling channel is defined, at least partially, by a radially outward channel surface and a radially inward channel surface;
wherein the stress-relief boss extends away from the radially outward channel surface to a surface of the stress-relief boss;
wherein a thickness of the radially outward wall between the radially outward surface and the surface of the stress-relief boss is greater than a thickness of the radially outward wall between the radially outward surface and the radially outward channel surface, and wherein a radial height of the cooling channel at a base of the stress-relief recess is greater than any other radial height of the cooling channel.
2. The method as in claim 1 , wherein the blade outer air seal segment further comprises:
a raised portion of the radially outward surface, wherein the radially outward channel surface is located radially outward of the radially inward channel surface, and wherein the inlet orifice extends from the raised portion of the radially outward surface to the surface of the stress-relief boss.
3. The method as in claim 1 , wherein the surface of the stress-relief boss is parallel to at least one of the radially inward channel surface and the radially outward channel surface.
4. The method as in claim 1 , wherein a radial height of the cooling channel between the radially outward channel surface and the radially inward channel surface is greater than a radial height of the cooling channel between the surface of the stress-relief boss and the radially inward channel surface.
5. The method as in claim 1 , wherein the stress-relief boss is concentric to the inlet orifice.
6. The method as in claim 1 , wherein the stress-relief boss is concentric to the stress-relief recess.
7. The method as in claim 1 , wherein the stress-relief recess extends into the radially outward channel surface to the base of the stress-relief recess.
8. The method as in claim 7 , wherein a radial height of the cooling channel between the radially outward channel surface and the radially inward channel surface is less than the radial height of the cooling channel between the base of the stress-relief recess and the radially inward channel surface.
9. The method as in claim 1 , wherein the inlet orifice is formed using electrical discharge machining.