Cooling schemes for airfoils for gas turbine engines

A core assembly for manufacturing an airfoil having a leading edge, a trailing edge, a pressure side wall extending between the leading edge and the trailing edge and defining a pressure side, and a suction side wall extending between the leading edge and the trailing edge and defining a suction side, wherein a plurality of cooling passages are formed within the airfoil and a mean camber line extends through the airfoil from the leading edge to the trailing edge, the core assembly comprising:

• a leading edge cavity core configured to define a leading edge cavity within a formed airfoil body that is defined along the leading edge to provide cooling to the leading edge of the formed airfoil;
• a trailing edge cavity core configured to define a trailing edge cavity within the formed airfoil body that is defined along the trailing edge to provide cooling to the trailing edge of the formed airfoil;
• a plurality of pressure side cavity cores configured to define a plurality of pressure side skin cavities arranged along an interior surface of the pressure side wall of the formed airfoil body, wherein at least one formed pressure side skin cavity wall does not extend to the suction side wall of the formed airfoil body;
• a plurality of suction side cavity cores configured to define a plurality of suction side skin cavities arranged along an interior surface of the suction side wall of the formed airfoil body, wherein at least one formed suction side skin cavity wall does not extend to the pressure side wall of the formed airfoil body;
• and
• a main body cavity core positioned axially between the leading edge cavity core and the trailing edge cavity core and circumferentially between the plurality of pressure side cavity cores and the plurality of suction side cavity cores,
• wherein the plurality of pressure side cavity cores and the plurality of suction side cavity cores are arranged in a staggered pattern in a direction from the leading edge cavity core to the trailing edge cavity core along the main body cavity core,
• wherein each side skin cavity core extends inward toward the mean camber line and at a respective inflection point, the respective side skin cavity core extends away from the mean camber line,
• wherein the main body cavity core has a zig-zag geometry extending from a leading edge end of the main body cavity core toward a trailing edge end of the main body cavity core,
• wherein the main body cavity core has a tapering thickness in a circumferential direction from the leading edge end of the main body cavity core toward the trailing edge end of the main body cavity core, wherein the tapering thickness decreases smoothly and the trailing edge end has a thickness that is at least 40% a thickness of the leading edge end.

An airfoil for a gas turbine engine, the airfoil comprising:

• an airfoil body having a leading edge, a trailing edge, a pressure side wall extending between the leading edge and the trailing edge and defining a pressure side, and a suction side wall extending between the leading edge and the trailing edge and defining a suction side, wherein a plurality of cooling passages are formed within the airfoil body, with a mean camber line extending through the airfoil body from the leading edge to the trailing edge;
• a leading edge cavity defined within the airfoil body and defined along the leading edge to provide cooling to the leading edge of the airfoil, wherein a leading edge interior rib defines an aft extent of the leading edge cavity;
• a trailing edge cavity defined within the airfoil body and defined along the trailing edge to provide cooling to the trailing edge of the airfoil, wherein a trailing edge interior rib defines a forward extent of the trailing edge cavity;
• a plurality of pressure side cavities defined by one or more pressure side skin cavity walls arranged along an interior surface of the pressure side wall, wherein at least one pressure side skin cavity wall does not extend to the suction side wall;
• a plurality of suction side cavities defined by one or more suction side skin cavity walls arranged along an interior surface of the suction side wall, wherein at least one suction side skin cavity wall does not extend to the pressure side wall;
• and
• a main body cavity extending between the leading edge interior rib and the trailing edge interior rib,
• wherein the plurality of pressure side cavities and the plurality of suction side cavities are arranged in a staggered pattern in a direction from the leading edge to the trailing edge, with the one or more pressure side skin cavity walls, the one or more suction side skin cavity walls, the leading edge interior rib, and the trailing edge interior rib defining the bounds of the main body cavity,
• wherein each pressure side skin cavity wall extends inward from the pressure side wall toward the mean camber line in a substantially straight line to a respective inflection point and the respective pressure side skin cavity wall extends back to the pressure side wall in a substantially straight line to form a zig-zag pattern along the pressure side wall,
• wherein each suction side skin cavity wall extends inward from the suction side wall toward the mean camber line in a substantially straight line to a respective inflection point and the respective suction side skin cavity wall extends back to the suction side wall in a substantially straight line to form a zig-zag pattern along the suction side wall, and
• wherein the main body cavity has zig-zag shape defined by the staggered, zig-zag pattern of the plurality of pressure side skin cavity walls and the plurality of suction side skin cavity walls,
• wherein a dimension of at least one suction side skin cavity wall, in a direction from the suction side toward the pressure side, extends greater than 50% and less than 100% across the airfoil body.