Method of manufacturing a fuel distributor

Abstract

A method for fabricating a unitary distributor is disclosed, the method comprising the steps of determining three-dimensional information of the unitary distributor having at least one flow passage having an arcuate portion located within a distributor ring body having an axis, converting the three-dimensional information into a plurality of slices that each define a cross-sectional layer of the unitary distributor and successively forming each layer of the unitary distributor by fusing a metallic powder using laser energy. A distributor is disclosed comprising a flow passage with an arcuate portion located in a distributor ring body wherein the distributor is made by using a rapid manufacturing process. A unitary fuel distributor comprising a fuel conduit and a distributor is disclosed wherein the unitary fuel distributor is made by using a rapid manufacturing process.

Description

CROSS-REFERENCE TO RELATED APPLICATIONS[0001]This Application claims priority to U.S. Provisional Application Ser. No. 61 / 044,116, filed Apr. 11, 2008, which is herein incorporated by reference in its entirety.BACKGROUND OF THE INVENTION[0002]This invention relates generally to fluid distributors, and more specifically to unitary fuel distributors for transporting fuel into fuel nozzles used in gas turbine engines.[0003]Turbine engines typically include a plurality of fuel nozzles for supplying fuel to the combustor in the engine. The fuel is introduced at the front end of a burner in a highly atomized spray from a fuel nozzle. Compressed air flows around the fuel nozzle and mixes with the fuel to form a fuel-air mixture, which is ignited by the burner. Because of limited fuel pressure availability and a wide range of required fuel flow, many fuel injectors include pilot and main nozzles, with only the pilot nozzles being used during start-up, and both nozzles being used during high...

AI Technical Summary

Benefits of technology

"The patent describes a method for making a unitary distributor with an arcuate portion located in a distributor ring body. The method involves determining the three-dimensional information of the distributor and converting it into a plurality of slices. Each layer of the distributor is then formed by fusing metallic powder using laser energy. The invention also includes a distributor with an arcuate portion located in a distributor ring body made by a rapid manufacturing process. Additionally, the invention includes a unitary fuel distributor with a fuel conduit and distributor made by a rapid manufacturing process. The technical effects of the invention include improved fuel distribution and reduced manufacturing costs."

Problems solved by technology

Because of limited fuel pressure availability and a wide range of required fuel flow, many fuel injectors include pilot and main nozzles, with only the pilot nozzles being used during start-up, and both nozzles being used during higher power operation.

Over time, continued exposure to high temperatures during turbine engine operations may induce thermal stresses in the conduits and fuel nozzles which may damage the conduits or fuel nozzle and may adversely affect their operation.

For example, thermal stresses may cause fuel flow reductions in the conduits and may lead to excessive fuel maldistribution within the turbine engine.

Exposure of fuel flowing through the conduits and orifices in a fuel nozzle to high temperatures may lead to coking of the fuel and lead to blockages and non-uniform flow.

To provide low emissions, modern fuel nozzles require numerous, complicated internal air and fuel circuits to create multiple, separate flame zones.

Furthermore, over time, continued operation with damaged fuel nozzles may result in decreased turbine efficiency, turbine component distress, and / or reduced engine exhaust gas temperature margin.

Conventional gas turbine engine components such as, for example, fuel nozzles and their associated conduits and distribution systems, are generally expensive to fabricate and / or repair because the conventional fuel nozzle designs having complex conduits and distribution circuits for transporting and distributing fuel include a complex assembly and joining of more than thirty components.

More specifically, the use of braze joints can increase the time needed to fabricate such components and can also complicate the fabrication process for any of several reasons, including: the need for an adequate region to allow for braze alloy placement; the need for minimizing unwanted braze alloy flow; the need for an acceptable inspection technique to verify braze quality; and, the necessity of having several braze alloys available in order to prevent the re-melting of previous braze joints.

Moreover, numerous braze joints may result in several braze runs, which may weaken the parent material of the component.

The presence of numerous braze joints can undesirably increase the weight and manufacturing cost of the component.

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