Impingement cooling apparatus for turbomachinery

Abstract

An integrated combustor nozzle (100) includes a combustion liner (110) extending radially between an inner liner section (106) and an outer liner section (108), the combustion liner (110) including a forward end portion (112), an aft end portion, a first sidewall (116), and a second sidewall (118). The aft end portion (114) of the combustion liner (110) defines a turbine nozzle (120). The combustion liner (110) defines a cavity (126) forward of the turbine nozzle (120). The cavity (126) extends between the first sidewall (116) and the second sidewall (118). An impingement cooling apparatus is positioned within the cavity (126). The impingement cooling apparatus includes a flange (310, 311). The impingement cooling apparatus further includes a plurality of impingement members (302) configured to direct a coolant to impinge on the first sidewall (116) and the second sidewall (118). Each impingement member (302) extends from a respective inlet (313) defined within the flange (310, 311) to a respective closed end (312). A plurality of impingement holes (304) are defined on each impingement member (302).

Description

Technical Field

[0001] This disclosure relates generally to integrated combustion nozzles for gas turbine engines. More specifically, this disclosure relates to various cooling components for integrated combustion nozzles.

[0002] Statement regarding federally funded research or development

[0003] This invention was completed with government support under contract number DE-FE0023965 granted by the U.S. Department of Energy. The government holds certain rights to this invention. Background Technology

[0004] Turbines are used in a variety of industries and applications for energy transfer purposes. For example, a gas turbine engine typically includes a compressor section, a combustion section, a turbine section, and an exhaust section. The compressor section gradually increases the pressure of the working fluid entering the gas turbine engine and supplies this compressed working fluid to the combustion section. The compressed working fluid and fuel (e.g., natural gas) mix in the combustion section and are burned in the combustion chamber to produce high-pressure, high-temperature combustion gases. The combustion gases flow from the combustion section into the turbine section, where they expand to do work. For example, the expansion of the combustion gases in the turbine section can cause a rotor shaft connected to, for example, a generator to rotate to generate electricity. The combustion gases then exit the gas turbine via the exhaust section.

[0005] In many turbine combustors, combustion gases are conveyed toward the inlet of the turbine section of the gas turbine via a hot gas path at least partially defined by a combustion liner that extends downstream from the fuel nozzle and terminates at the turbine section inlet. Therefore, the high combustion gas temperature within the turbine section typically corresponds to greater thermal and kinetic energy transfer between the combustion gases and the turbine, thereby enhancing the overall power output of the turbine. However, high combustion gas temperatures can lead to corrosion, creep, and / or low-cycle fatigue in various combustor components, thus limiting its overall durability.

[0006] Therefore, it is necessary to cool the burner components, which is typically achieved by delivering a cooling medium (such as compressed working fluid from the compressor section) to the various parts of the combustion bushing. However, utilizing most of the compressed working fluid from the compressor section can adversely affect the overall operating efficiency of the turbine, as this reduces the amount of working fluid used in the turbine section.

[0007] Therefore, an improved system for cooling turbine combustors is desired in the art. Specifically, a system that effectively utilizes the compressed working fluid from the compressor would be useful. Summary of the Invention

[0008] The aspects and advantages of the components according to this disclosure will be set forth in part in the following description, or may be apparent from the description, or may be learned by practice of the technology.

[0009] According to one embodiment, an integrated burner nozzle is provided. The integrated burner nozzle includes a combustion bushing extending radially between an inner bushing section and an outer bushing section. The combustion bushing includes a front end portion, a rear end portion, a first sidewall, and a second sidewall. The rear end portion of the combustion bushing defines a turbine nozzle. The combustion bushing defines a cavity in front of the turbine nozzle. The cavity extends between the first and second sidewalls. The integrated burner nozzle also includes an impact cooling device positioned within the cavity. The impact cooling device includes a flange. The impact cooling device also includes a plurality of impact members configured to guide coolant to impact the first and second sidewalls. Each of the plurality of impact members extends from a corresponding inlet defined within the flange to a corresponding closed end. A plurality of impact holes are defined on each of the plurality of impact members.

[0010] According to another embodiment, a turbine is provided. The turbine includes a compressor and a compressor discharge housing disposed downstream of the compressor. The turbine also includes a turbine disposed downstream of the compressor discharge housing. The turbine further includes an annular combustion system disposed within the compressor discharge housing. The annular combustion system includes a plurality of integrated burner nozzles arranged in an annular array around an axial centerline of the turbine. Each integrated burner nozzle includes a combustion bushing extending radially between an inner bushing section and an outer bushing section, the combustion bushing including a front end portion, a rear end portion, a first sidewall, and a second sidewall. The rear end portion of the combustion bushing defines a turbine nozzle. The combustion bushing defines a cavity in front of the turbine nozzle. The cavity extends between the first and second sidewalls. The integrated combustion nozzle also includes an impact cooling device positioned within the cavity. The impact cooling device includes a flange. The impact cooling device also includes a plurality of impact members configured to guide coolant to impact the first and second sidewalls. Each of the plurality of impact members extends from a corresponding inlet defined within the flange to a corresponding closed end. A plurality of impact holes are defined on each of the plurality of impact members.

[0011] These and other features, aspects, and advantages of the components of the present invention will become more readily understood with reference to the following description and the appended claims. The accompanying drawings, which are incorporated in and form a part of this specification, illustrate embodiments of the technology and, together with the description, serve to explain the principles of the technology. Attached Figure Description

[0012] This specification sets forth a complete and practicable disclosure of the components of the invention as understood by one of ordinary skill in the art, with reference to the accompanying drawings, including the best mode for making and using the systems and methods of the invention, wherein:

[0013] Figure 1 This is a schematic diagram of a turbine according to an embodiment of this disclosure;

[0014] Figure 2 This is an upstream view of an exemplary combustion section of a turbine according to an embodiment of this disclosure;

[0015] Figure 3 This is a perspective view of the integrated burner nozzle as seen from a first side according to an embodiment of this disclosure;

[0016] Figure 4 This is a perspective view of the integrated burner nozzle as seen from the second side according to an embodiment of this disclosure;

[0017] Figure 5 This is a perspective view of an integrated burner nozzle according to an embodiment of the present disclosure, which is shown having various disassembled cooling components;

[0018] Figure 6 This is a schematic cross-sectional view of an integrated burner nozzle along the radial direction of a turbine, according to an embodiment of this disclosure;

[0019] Figure 7 This is an enlarged cross-sectional view of a portion of the outer bushing section of an integrated burner nozzle according to an embodiment of this disclosure;

[0020] Figure 8 This is an enlarged cross-sectional view of a portion of the inner liner section of an integrated burner nozzle according to an embodiment of this disclosure;

[0021] Figure 9 This is a plan view of an embodiment of the present disclosure along the radial direction R of two impact panels and a cooling insert, which are isolated from other components of the integrated burner nozzle;

[0022] Figure 10 This is a cross-sectional view of the panel section of the impact panel along the axial direction A of the turbine, according to an embodiment of this disclosure;

[0023] Figure 11 It is according to the embodiment of this disclosure along the radial direction R of the turbine. Figure 10 A plan view of the panel section shown;

[0024] Figure 12 This is a cross-sectional perspective view of a panel segment according to an embodiment of this disclosure;

[0025] Figure 13 It is along the central axis according to the embodiments of this disclosure. Figures 10 to 12 A plan view of the first end of the panel segment shown;

[0026] Figure 14 It is along the central axis according to the embodiments of this disclosure. Figures 10 to 12 A plan view of the second end of the panel section shown;

[0027] Figure 15 This is a schematic view / block diagram of an additive manufacturing system for generating objects according to an embodiment of this disclosure;

[0028] Figure 16 This is a flowchart of a method for manufacturing an impact panel according to an embodiment of this disclosure;

[0029] Figure 17 This is a perspective view of an impact cooling device according to an embodiment of the present disclosure, which is isolated from and positioned on a building plate by an integrated burner nozzle, and wherein one of the row of impact members has been removed;

[0030] Figure 18 This is an enlarged cross-sectional view of an integrated burner nozzle along the radial direction R of a turbine, according to an embodiment of the present disclosure, wherein an impingement cooling device is positioned within the cavity of the integrated burner nozzle;

[0031] Figure 19 This is a cross-sectional view of a single impact member according to an embodiment of this disclosure;

[0032] Figure 20 An enlarged cross-sectional view of an impact member along the radial direction R of the turbine and a portion of two adjacent impact members according to an embodiment of this disclosure;

[0033] Figure 21 An enlarged view of the impact wall support before the removal of excess material according to an embodiment of this disclosure;

[0034] Figure 22 An enlarged view of the impact wall support after removing excess material according to an embodiment of this disclosure;

[0035] Figure 23 A flowchart illustrating a method for manufacturing an impact cooling device according to an embodiment of the present invention;

[0036] Figure 24 This is a perspective view of a cooling insert isolated from other components of the integrated burner nozzle, according to an embodiment of this disclosure;

[0037] Figure 25This is a cross-sectional view of the cooling insert along the axial direction A of the turbine according to an embodiment of this disclosure;

[0038] Figure 26 This is a cross-sectional view of the cooling insert along the radial direction R of the turbine according to an embodiment of this disclosure;

[0039] Figure 27 This is a cross-sectional view of a cooling insert along the circumferential direction C of the turbine according to an embodiment of this disclosure; and

[0040] Figure 28 This is an enlarged view of two oppositely arranged cooling inserts according to an embodiment of this disclosure. Detailed Implementation

[0041] Reference will now be made in detail to embodiments of the components of the present invention, one or more examples of which are illustrated in the accompanying drawings. Each example is provided by way of explanation of the inventive technique and not as a limitation thereof. Indeed, it will be apparent to those skilled in the art that modifications and variations may be made to the inventive technique without departing from the scope or spirit of the technique protected by the claims. For example, a feature shown or described as part of one embodiment may be used in another embodiment to produce yet another embodiment. Therefore, this disclosure is intended to cover such modifications and variations that fall within the scope of the appended claims and their equivalents.

[0042] The detailed description uses numbers and letters to refer to feature structures in the drawings. Similar or analogous names in the drawings and description have been used to refer to similar or analogous parts of the invention. As used herein, the terms "first," "second," and "third" are used interchangeably to distinguish one part from another and are not intended to indicate the location or importance of the various parts.

[0043] As used herein, the terms “upstream” (or “upward”) and “downstream” (or “downward”) refer to the relative directions of fluid flow within a fluid passage. For example, “upstream” refers to the direction from which fluid flows, and “downstream” refers to the direction towards which fluid flows. The term “radial” refers to a relative direction substantially perpendicular to the axial centerline of a particular component, the term “axial” refers to a relative direction substantially parallel and / or coaxially aligned with the axial centerline of a particular component, and the term “circumferential” refers to a relative direction extending around the axial centerline of a particular component. Approximate terms, such as “generally,” “substantially,” “about,” or “approximately,” include values ​​greater than or less than ten percent of the specified value. When used in the context of an angle or direction, such terms include values ​​greater than or less than ten degrees of said angle or direction. For example, “generally vertical” includes directions within ten degrees of vertical along any direction (e.g., clockwise or counterclockwise).

[0044] The terminology used herein is for the purpose of describing particular embodiments only and is not intended to be limiting. As used herein, the singular forms “a,” “an,” and “the” are intended to include the plural forms as well, unless the context clearly indicates otherwise. It will be further understood that, when used in the specification, the terms “comprising” and / or “including” specify the presence of stated features, integers, steps, operations, elements, and / or components, but do not exclude the presence or addition of one or more other features, integers, steps, operations, elements, components, and / or groups thereof.

[0045] Now refer to the attached diagram, Figure 1 A schematic diagram of one embodiment of a turbine is shown, which in the illustrated embodiment is a gas turbine 10. Although industrial or land-based gas turbines are shown and described herein, this disclosure is not limited to land-based and / or industrial gas turbines unless otherwise specified in the claims. For example, the invention described herein can be used with any type of turbine, including but not limited to steam turbines, aircraft gas turbines, or marine gas turbines.

[0046] As shown in the figure, the gas turbine 10 generally includes an inlet section 12, a compressor 14 disposed downstream of the inlet section 12, a combustion section 16 disposed downstream of the compressor 14, a turbine 18 disposed downstream of the combustion section 16, and an exhaust section 20 disposed downstream of the turbine 18. Furthermore, the gas turbine 10 may include one or more shafts 22 that connect the compressor 14 to the turbine 18.

[0047] During operation, air 24 flows through inlet section 12 and into compressor 14, where it is gradually compressed, thereby supplying compressed air 26 to combustion section 16. At least a portion of the compressed air 26 mixes with fuel 28 in combustion section 16 and is burned to produce combustion gas 30. Combustion gas 30 flows from combustion section 16 into turbine 18, where energy (kinetic and / or thermal energy) is transferred from combustion gas 30 to rotor blades (not shown), causing shaft 22 to rotate. This mechanical rotational energy can then be used for various purposes, such as powering compressor 14 and / or generating electricity. Combustion gas 30 exiting turbine 18 can then be discharged from gas turbine 10 via exhaust section 20.

[0048] Figure 2 An upstream view of combustion section 16 according to various embodiments of this disclosure is provided. For example... Figure 2 As shown, the combustion section 16 may be at least partially surrounded by an external or compressor discharge housing 32. The compressor discharge housing 32 may at least partially define a high-pressure chamber 34, which at least partially surrounds various components of the burner 16. The high-pressure chamber 34 may be connected to the compressor 14 ( Figure 1Fluid communication is maintained to receive compressed air 26 from the compressor. In various embodiments, such as... Figure 2 As shown, the combustion section 16 includes a segmented annular combustion system 36, which includes a plurality of integrated burner nozzles 100 arranged circumferentially around the axial centerline 38 of the gas turbine 10, which may coincide with the gas turbine shaft 22.

[0049] Figure 3 A perspective view of the integrated burner nozzle 100, viewed from the first side, is provided. Similarly, Figure 4 A perspective view of the integrated burner nozzle 100, viewed from a second side, according to an embodiment of this disclosure is provided. Figure 2 , Figure 3 and Figure 4 As shown herein, the segmented annular combustion system 36 includes a plurality of integrated burner nozzles 100. As further described herein, each burner nozzle 100 includes a first sidewall 116 and a second sidewall 118. In a particular embodiment, the first sidewall is a pressure sidewall, and the second sidewall is a suction sidewall, based on the integration of the sidewalls with the corresponding pressure and suction sides of the downstream turbine nozzle 120. It should be understood that any reference herein to pressure sidewalls and suction sidewalls represents a particular embodiment, such references are for discussion purposes, and such references are not intended to limit the scope of any embodiment unless the specific context otherwise requires.

[0050] like Figure 3 and Figure 4 As shown, each circumferentially adjacent pair of burner nozzles 100 defines a corresponding main combustion zone 102 and a corresponding auxiliary combustion zone 104 between them, thereby forming an annular array of main combustion zones 102 and auxiliary combustion zones 104. The main combustion zones 102 and auxiliary combustion zones 104 are circumferentially separated or fluidly isolated from adjacent main combustion zones 102 and auxiliary combustion zones 104 by combustion bushings 110, respectively.

[0051] like Figure 3 and Figure 4 As shown, each burner nozzle 100 includes an inner bushing section 106, an outer bushing section 108, and a hollow or semi-hollow combustion bushing 110 extending between the inner bushing section 106 and the outer bushing section 108. It is conceivable that more than one (e.g., two, three, four, or more) combustion bushings 110 may be positioned between the inner bushing section 106 and the outer bushing section 108, thereby reducing the number of joints between adjacent inner bushing sections requiring sealing. For ease of discussion herein, reference will be made to an integrated burner nozzle 100 having a single combustion bushing 110 between the respective inner bushing section 106 and the outer bushing section 108, but a 2:1 bushing section to combustion bushing ratio is not required. Figure 3 and Figure 4As shown, each combustion bushing 110 includes a front end portion or upstream end portion 112, a rear end portion or downstream end portion 114, and in Figure 3 The specific example embodiment shown is the first sidewall 116 of the pressure sidewall and in Figure 4 The specific example implementation shown is the second sidewall 118 of the suction sidewall.

[0052] The segmented annular combustion system 36 further includes a fuel injection module 117. In the illustrated example embodiment, the fuel injection module 117 includes a plurality of fuel nozzles. The fuel injection module 117 is configured to be mounted in the front end portion 112 of a respective combustion bushing 110. For the purposes of this illustration, the fuel injection module 117 including a plurality of fuel nozzles may be referred to as a “bubble fuel nozzle.” However, the fuel injection module 117 may include or contain any type of fuel nozzle or burner (such as a vortex fuel nozzle or a swirl nozzle), and unless specifically stated otherwise, the claims should not be limited to a bubble fuel nozzle.

[0053] Each fuel injection module 117 may extend circumferentially between two circumferentially adjacent combustion bushings 110 and / or extend radially between a corresponding inner bushing section 106 and an outer bushing section 108 of the respective burner nozzle 100. During axial staged fuel injection operation, the fuel injection module 117 provides a flow of premixed fuel and air (i.e., a first combustible mixture) to the corresponding main combustion zone 102.

[0054] In at least one implementation, such as Figure 3 and Figure 4 As shown, the downstream end portions 114 of one or more of the combustion bushings 110 transition into a generally airfoil-shaped turbine nozzle 120, which guides and accelerates the combustion products toward the turbine blades. Therefore, the downstream end portion 114 of each combustion bushing 110 can be considered as an airfoil without a leading edge. When the integrated burner nozzle 100 is installed within the combustion section 16, the turbine nozzle 120 can be positioned upstream of the turbine rotor blade stage of the turbine 18.

[0055] As used herein, the term "integrated burner nozzle" refers to a seamless structure comprising a combustion bushing 110, a turbine nozzle 120 located downstream of the combustion bushing, an inner bushing section 106 (embodied by the turbine nozzle 120) extending from a front end 112 to a rear end 114 of the combustion bushing 110, and an outer bushing section 108 (embodied by the turbine nozzle 120) extending from the front end 112 to the rear end 114 of the combustion bushing 110. In at least one embodiment, the turbine nozzle 120 of the integrated burner nozzle 100 serves as a first-stage turbine nozzle and is positioned upstream of the first stage of the turbine rotor blades.

[0056] As described above, one or more integrated burner nozzles 100 are formed as an integral or monolithic structure or body comprising an inner bushing section 106, an outer bushing section 108, a combustion bushing 110, and a turbine nozzle 120. The integrated burner nozzle 100 can be manufactured as an integrated or seamless component via casting, additive manufacturing (such as 3D printing), or other manufacturing techniques. By forming the burner nozzle 100 as a monolithic or integrated component, the need for sealing between the various features of the burner nozzle 100 can be reduced or eliminated, the number of parts and cost can be reduced, and assembly steps can be simplified or eliminated. In other embodiments, the burner nozzle 100 can be manufactured, for example, by welding, or can be formed by different manufacturing techniques, wherein components made using one technique are joined to components made using the same or another technique.

[0057] In certain embodiments, at least a portion or all of each integrated burner nozzle 100 may be formed of a ceramic matrix composite (CMC) or other composite material. In other embodiments, a portion or all of each integrated burner nozzle 100 (more specifically, turbine nozzle 120 or its trailing edge) may be made of a highly oxidation-resistant material (e.g., coated with a thermal barrier coating), or may be coated with a highly oxidation-resistant material.

[0058] In another embodiment (not shown), at least one of the combustion bushings 110 may taper to a trailing edge aligned with the longitudinal (axial) axis of the combustion bushing 110. That is, the combustion bushing 110 may not be integrated with the turbine nozzle 120. In these embodiments, it may be desirable to have a non-uniform number of combustion bushings 110 and turbine nozzles 120. Conical combustion bushings 110 (i.e., those without integrated turbine nozzles 120) may be used alternately with combustion bushings 110 with integrated turbine nozzles 120 (i.e., integrated burner nozzles 100) or in some other mode.

[0059] At least one of the combustion bushings 110 may include at least one cross flame tube (or traverse flame tube) 122 extending through corresponding openings in the pressure sidewall 116 and suction sidewall 118 of the respective combustion bushing 110. The cross flame tube 122 allows for cross flames and ignition of circumferentially adjacent main combustion zones 102 between circumferentially adjacent integrated burner nozzles 100.

[0060] In many implementations, such Figure 3 As shown, each combustion bushing 110 may include a plurality of radially spaced pressure-side injection outlets 164 defined along a pressure-side wall 116, through which pressure-side fuel injectors 160 may extend. Figure 6 ).like Figure 4As shown, each combustion bushing 110 may include a plurality of radially spaced suction-side injection outlets 165 defined along a suction sidewall 118, through which a suction-side fuel injector 161 may extend. Figure 6 Each corresponding main combustion zone 102 is defined upstream of the corresponding pressure-side injection outlet 164 and / or suction-side injection outlet 165 of a pair of circumferentially adjacent integrated burner nozzles 100. Each auxiliary combustion zone 104 is defined downstream of the corresponding pressure-side injection outlet 164 and / or suction-side injection outlet 165 of the pair of circumferentially adjacent integrated burner nozzles 100. Although multiple pressure-side injection outlets 164 are located upstream of the corresponding pressure-side injection outlet 164 and / or suction-side injection outlet 165 of the pair of circumferentially adjacent integrated burner nozzles 100, each auxiliary combustion zone 104 is defined downstream of the corresponding pressure-side injection outlet 164 and / or suction-side injection outlet 165 of the pair of circumferentially adjacent integrated burner nozzles 100. Figure 2 The nozzle is shown as residing in a common radial or injection plane relative to the axial centerline of the integrated burner nozzle 100, or at a common axial distance from the downstream end portion 114 of the fuel injection panel 110. However, in certain embodiments, one or more pressure-side injection outlets 164 may be axially staggered relative to radially adjacent pressure-side injection outlets 164, thereby offsetting the axial distance from the pressure-side injection outlet 164 to the downstream end portion 114 for a particular pressure-side injection outlet 164. Similarly, although... Figure 4 A plurality of suction-side injection outlets 165 are shown in a common radial or injection plane or at a common axial distance from the downstream end portion 114 of the fuel injection panel 110. However, in a particular embodiment, one or more suction-side injection outlets 165 may be axially staggered relative to radially adjacent suction-side injection outlets 165, thereby offsetting the axial distance from the pressure-side injection outlet 165 to the downstream end portion 114 for a particular suction-side injection outlet 165.

[0061] During operation of the segmented annular combustion system 36, it may be necessary to cool one or more of the pressure sidewall 116, suction sidewall 118, turbine nozzle 120, inner bushing section 106, and / or outer bushing section 108 of each integrated burner nozzle 100 in order to enhance the overall mechanical properties of each integrated burner nozzle 100 and the segmented annular combustion system 36. To accommodate cooling requirements, each integrated burner nozzle 100 may include various air passages or cavities, and these air passages or cavities may be in fluid communication with the high-pressure chamber 34 formed within the compressor discharge housing 32 and / or with the premixed air chamber 144 defined within each combustion bushing 110.

[0062] Figure 5A perspective view of an integrated burner nozzle 100 according to an embodiment of the present disclosure is shown, the integrated burner nozzle being shown as having various disassembled cooling components. In various embodiments, as shown, an internal portion of each combustion bushing 110 may be defined between a pressure sidewall 116 and a suction sidewall 118, and may be partitioned into various air passages or cavities 124, 126 by one or more ribs 128, 129. In a particular embodiment, the air cavities 124, 126 may receive air from a compressor discharge housing 32 or other cooling source. Ribs or baffles 128, 129 may extend within the internal portion of the combustion bushing 110 to at least partially form or separate a plurality of air cavities 124, 126. In a particular embodiment, some or all of the ribs 128, 129 may provide structural support for the pressure sidewall 116 and / or suction sidewall 118 of the combustion bushing 110.

[0063] In a specific implementation, such as Figure 5 As shown, each integrated burner nozzle 100 may include one or more outer impact panels 130 extending along the outer surface 131 of the outer bushing segment 108. The outer impact panels 130 may have a shape corresponding to the shape or a portion of the shape of the outer bushing segment 108. In many embodiments, the outer impact panels 130 may define a plurality of impact holes 139 defined at various locations along the outer impact panels 130. Figure 7 In many implementations, such as Figure 3 and Figure 4 As shown in the optimal configuration, the outer impact panel 130 can be disposed on both sides of the cavities 124, 126 to provide impact cooling to the entire outer bushing section 108.

[0064] Similarly, each integrated burner nozzle 100 may include an inner impact panel 134 extending along the outer surface 135 of the inner bushing segment 106. The inner impact panel 134 may have a shape corresponding to the shape or a portion of the shape of the inner bushing segment 106. In many embodiments, such as Figure 3 and Figure 4 As shown in the optimal configuration, the inner impact panel 134 can be disposed on both sides of the cavities 124, 126 to provide impact cooling to the entire inner bushing section 106.

[0065] like Figure 5As shown, one or more integrated burner nozzles in the integrated burner nozzle 100 may further include a cooling insert 400 positioned near the front end 112 of the combustion bushing 110 and an impact cooling device 300 positioned near the rear end 114 of the combustion bushing 110. As shown and detailed below, the cooling insert 400 may be positioned within the cavity 124 such that it is received within the interior of the combustion bushing 110 to provide cooling thereto. Similarly, the impact cooling device 300 may be received within the cavity 126 such that it is received within the interior of the combustion bushing 110 to provide cooling thereto. As described in more detail below, both the cooling insert 400 and the impact cooling device 300 may be formed as substantially hollow (or semi-hollow) structures, having openings at one or both ends with a shape complementary to that of the air cavity 126. During operation, air from the compressor discharge housing 32 may flow through one or both of the cooling insert 400 and / or the impact cooling device 300, whereby the air flows as a diffused stream through the impact orifice, impacting the inner surface of the combustion bushing 110, thereby allowing heat to be convectively transferred from the inner surface of the combustion bushing 110 to the cooling air. As discussed in detail below, after impacting the inner surface of the combustion bushing 110, a portion of the air passing through the cooling insert 400 and / or the impact cooling device 300 may flow through the combustion bushing 110 toward the fuel injector, whereby the air may be mixed with fuel and used for combustion in the auxiliary combustion zone 104. In this way, the air used to cool the combustion bushing 110 is also used to do work in the turbine section 18, thereby improving the overall efficiency of the gas turbine 10.

[0066] In many embodiments, as shown, two cooling inserts 400 may be installed within the air cavity 124, such as a first cooling insert 400 installed through the inner bushing section 106 and a second cooling insert 400 installed through the outer bushing section 108. Such an assembly may be useful when the integrated burner nozzle 100 includes a cross-flame tube 122, which prevents a single impingement air insert 400 from being inserted through the radial dimension of the cavity 124. Alternatively, two or more impingement air inserts 400 may be installed in the axial direction A (axial direction A in, for example...) Figure 6 (represented in the middle) are sequentially positioned within a given cavity, for example, on either side of the cross flame tube 122.

[0067] Figure 6 A schematic cross-sectional view of an integrated burner nozzle 100 according to an embodiment of this disclosure is shown. Figure 6As shown, the integrated burner nozzle 100 may further include pressure-side fuel injectors 160. In many embodiments, the integrated burner nozzle 100 may include a plurality of pressure-side fuel injectors 160 spaced apart from each other in a radial direction R. For example, each pressure-side fuel injector 160 may extend from an inlet 162 located within the combustion bushing 110 near the suction sidewall 118 to a pressure-side injection outlet 164. Similarly, in many embodiments, the integrated burner nozzle 100 may include a plurality of suction-side fuel injectors 161 spaced apart from each other in a radial direction R. For example, each suction-side fuel injector 161 may extend from an inlet 166 located within the combustion bushing 110 near the pressure sidewall 116 to a suction-side injection outlet 165. The fuel injectors 160, 161 may provide an auxiliary mixture of fuel and air to the auxiliary combustion zone 104 downstream of the main combustion zone 102 to increase the temperature of the combustion gases before they enter the turbine section 18 and are used for work.

[0068] In various implementation schemes, such as Figure 6 As shown, fuel injectors 160 and 161 can be axially positioned between the cooling insert 400 and the impact cooling device 300. In a particular embodiment, the pressure-side fuel injector 160 can be axially positioned between the impact cooling device 300 and the suction-side fuel injector 161. Similarly, the suction-side fuel injector 161 can be axially positioned between the cooling insert 400 and the pressure-side fuel injector 160.

[0069] In a particular embodiment, the integrated burner nozzle 100 may include a frame 168 and ribs 128, 129. The frame 168 may extend around and support the fuel injector 160, 161. Furthermore, the frame 168 may at least partially define the path of air before it enters the fuel injectors 160, 161. Each of the ribs 128, 129 may extend between a pressure sidewall 116 and a suction sidewall 118. Figure 6 As shown, ribs 128, 129 may include one or more openings defined therethrough to provide fluid communication between fuel injectors 160, 161 and cooling insert 400 or shock cooling device 300.

[0070] As shown in the figure, various arrows indicate the airflow path within the combustion bushing 110. For example, the integrated burner nozzle 100 may further include pre-impact air 152 and post-impact air or used cooling air 154. Figure 6 As shown, the pre-impact air 152 can pass through a plurality of first impact holes 404 respectively defined on each of the walls 402 and 403. Figure 24 ) and the second and multiple impact holes 405 ( Figure 25The air exits the cooling insert 400. Similarly, the pre-impact air 152 can be delivered via a means defined in each impact member 302. Figure 17 Multiple impact holes 304 on the impact cooling device 300 exit. The size and orientation of the impact holes 304, 404, 405 can be configured to guide pre-impact air 152 to impact the inner surface 156 of the pressure sidewall 116 or the inner surface 158 of the suction sidewall 118 in the form of a discrete air jet. The discrete air jet impacts (or impinges) the inner surfaces 156, 158 and creates a thin air boundary layer on the inner surfaces, which allows for optimal heat transfer between the walls 116, 118 and the air. For example, the impact holes 304, 404, 405 can be oriented to pre-impact the air such that it is perpendicular to the surface it impacts, such as the inner surfaces 156, 158 of the walls 116, 118. Once the air has impacted the inner surfaces 156, 158, it can be referred to as "post-impact air" and / or "used cooling air" because the air has undergone energy transfer and therefore has different properties. For example, the used cooling air 154 may have a higher temperature and lower pressure than the pre-impact air 152 because the used cooling air 154 has removed heat from the combustion bushing 110 during the impact process.

[0071] Referencing the airflow path leaving the impact cooling device 300, such as... Figure 6 As shown, pre-impact air 152 exits each impact member 302 through multiple impact holes 304 and impacts the inner surfaces 156, 158 of the sidewalls 116, 118. During this process, the air undergoes energy transfer by removing heat from the sidewalls 116, 118, thus becoming post-impact air 154. Then, the post-impact air 154 reverses direction and flows through the gap 172 defined between the impact members 302. Figure 18 ).like Figure 6 As shown, the impact cooling device 300 may further define a collection passage 174 that receives post-impact air 154 from a gap 172 defined between the impact members 302. Both the gap 172 and the collection passage 174 advantageously provide a path for the post-impact air 154 to travel away from the pre-impact air 152. This is advantageous because it prevents the post-impact air 154 from obstructing (i.e., flowing through and disturbing) the flow of the pre-impact air 152, allowing the pre-impact air 152 to maintain its high velocity and effectively cool the walls 116, 118. Once the post-impact air 154 is within the collection passage 174, it can flow in a direction generally opposite to the axial direction A (i.e., opposite to the direction of the combustion gases). Figure 6As shown, the post-impact air 154 can flow from the collection passage 174 through one or more holes defined in the rib 129, flow around the pressure-side fuel injector 160, and flow into the inlet 166 of the suction-side fuel injector 161. In this way, all the air flowing through the impact cooling device 300 is used for both impact cooling and combustion gas generation, which minimizes the amount of exhaust air from the compressor section 14, thereby improving the overall performance of the gas turbine 10.

[0072] Now refer to the airflow path leaving the cooling plug 400, such as Figure 6 As shown, the pre-impact air 152 exits the walls 402 and 403 through multiple impact holes 404 and 405 and impacts the inner surfaces 156 and 158 of the sidewalls 116 and 118. At this time, the air undergoes energy transfer by removing heat from the sidewalls 116 and 118, thus becoming post-impact air 154. A portion of the post-impact air 154 then changes direction and flows in the opposite direction to the axial direction A (i.e., the opposite direction to the combustion gas direction). Figure 6 As shown, the post-impact air 154 can then reverse direction and travel in parallel through the collection passage 406 defined between walls 402, 403. The collection passage 406 can guide the post-impact air 154 toward the pressure-side fuel injector 160. In this way, the collection passage 406 advantageously provides a path for the post-impact air 154 away from the pre-impact air 152. This is advantageous because it prevents the post-impact air 154 from obstructing (i.e., flowing through and disturbing) the flow of the pre-impact air 152, which allows the pre-impact air 152 to maintain its high speed and effectively cool the walls 116, 118. Once the post-impact air 154 is within the collection passage 406, it can be directed toward the inlet 162 of the pressure-side fuel injector 160. For example, the post-impact air 154 can flow from the collection passage 406 through one or more openings defined in the rib 128, flow around the suction-side fuel injector 161, and flow into the inlet 162 of the pressure-side fuel injector 160. In this way, all the air flowing through the cooling insert 400 is used for both shock cooling and combustion gas generation, which minimizes the amount of exhaust air from the compressor section 14, thereby improving the overall performance of the gas turbine 10.

[0073] Figure 7 An enlarged cross-sectional view of a portion of the outer bushing section 108 according to an exemplary embodiment of the integrated burner nozzle 100 is shown, and Figure 8 An enlarged cross-sectional view of a portion of the inner bushing section 106 is shown. In many embodiments, the integrated combustion nozzle 100 may include an outer impact panel 130 and an inner impact panel 134 on either side of the combustion bushing 110 to provide impact cooling to the entire outer bushing section 108 and inner bushing section 106.

[0074] like Figure 7 and Figure 8 As shown, both the outer impact panel 130 and the inner impact panel 134 may include impact plates 136 disposed along the outer surfaces 131, 135 of the outer bushing section 108 and the inner bushing section 106, respectively. For example, the impact plate 136 of the outer impact panel 130 may be disposed along the outer surface 131 (i.e., the radial outer surface) of the outer bushing section 108. Similarly, the impact plate 136 of the inner impact panel 134 may be disposed along the outer surface 135 (i.e., the radial inner surface) of the inner bushing section 106. In an exemplary embodiment, as shown, each impact plate 136 may be spaced apart from the corresponding outer surfaces 131, 135 in a radial direction R to form a cooling flow gap 138 between them. For example, relative to the outer impact panel 130, the impact plate 136 may be spaced outwardly from the outer surface 131 of the outer bushing section in a radial direction R, thereby forming a cooling flow gap 138 between them. Similarly, the impact plate 136 of the inner impact panel 134 may be spaced inwardly from the outer surface 135 of the inner bushing section 106 in the radial direction R, thereby forming a cooling flow gap 138 between them.

[0075] like Figure 7 and Figure 8 As shown, various arrows can indicate the flow paths of air within the impact panels 130, 134. In an exemplary embodiment, the high-pressure chamber 34 can be fluidly communicated with the cooling flow gap 138 via a plurality of impact holes 139 defined in a radial direction R through the impact plate 136. Specifically, the size and orientation of the impact holes 139 can be configured to guide pre-impact air 152 from the high-pressure chamber 34 to impact the outer surfaces 131, 135 of the outer bushing section 108 and the inner bushing section 106 in the form of a diffused flow. The discrete pre-impact air jets 152 can then impact (or impinge) the outer surfaces 131, 135 and form a thin air boundary layer on the outer surfaces 131, 135, which allows for optimal heat transfer between the bushing sections 106, 108 and the air. Once the air has impacted the outer surfaces 131, 135, it can be referred to as “post-impact air” and / or “used cooling air” because the air has undergone energy transfer and therefore has different properties. For example, the used cooling air 154 may have a higher temperature and lower pressure than the pre-impact air 152 because it removes heat from the combustion bushing sections 106, 108 during the impact process.

[0076] In an exemplary embodiment, the inlet portion 140 extends from the impact plate 136 to the collection conduit 142. For example... Figure 7As shown, the collection conduit 142 defines a collection channel 144 that receives impinged air 154 from the cooling flow gap 138 via an inlet portion 140 and directs the impinged air 154 toward the low-pressure inlet 408 of the cooling insert 400 to the fuel injectors 160, 161. Figure 6 Used within. In many implementations, such as Figure 7 As shown, inlet portion 140 can provide a passage between cooling flow gap 138 and collection channel 144. For example, inlet portion 140 can extend directly from impact plate 136 to collection channel 142, such that inlet portion 140 fluidly connects cooling flow gap 138 directly to collection channel 144. In various embodiments, such as Figure 10 As shown, the inlet portion 140 may include sidewalls 150 spaced apart from each other. The sidewalls 150 may extend axially parallel to each other along the impact plate 130, such that they define an elongated slotted opening 188 through the impact plate 136. Figure 11 This allows air 154 to pass through after the impact.

[0077] In a specific implementation, such as Figure 10 As shown, each collection conduit 142 may have a cross-sectional shape defining a rectangular region. For example, each collection conduit 142 may include a radially inward wall 146, a radially outward wall 148, and a sidewall 141 extending between the radially inward wall 146 and the radially outward wall 148. In a particular embodiment, the sidewall 141 of the collection conduit 142 may be parallel to each other and longer than the radially inward / outward walls 146, 148, which advantageously allows the collection conduit 142 to have a larger collection area without overlapping with the impact orifice 139 and causing obstruction of airflow between the high-pressure chamber 34 and the cooling flow gap 138. In other embodiments (not shown), the collection conduit may have any suitable cross-sectional shape, such as circular, elliptical, rhomboid, square, or other suitable polygonal shapes, and therefore should not be limited to any particular cross-sectional shape unless specifically described in the claims.

[0078] like Figure 10 As shown, the inlet portion 140 may define a first width 176, and the collection conduit 142 may define a second width 178. More specifically, the first width 176 may be defined between the sidewalls 150 of the inlet portion 140. Similarly, the second width 178 of the collection conduit 142 may be defined between the sidewalls 141 of the collection conduit 142. It may be advantageous to make the first width 176 as small as possible relative to the second width 178 of the collection conduit 142 in order to maximize the amount of area that can be cooled by the impact plate 136. For example, in an exemplary embodiment, the second width 178 of the collection conduit 142 may be larger than the first width 176 of the inlet portion 140.

[0079] In many implementations, such Figure 9 As shown, the collection conduit 142 may be a first collection conduit 142', and the impact panel 130 may further include a second collection conduit 142'' extending from the impact panel 130. As shown, the first collection conduit 142' and the second collection conduit 142'' may be spaced apart from each other and may extend generally parallel to each other in the axial direction A. In such embodiments, each collection conduit 142', 142'' may be coupled to the impact plate 136 via a respective inlet portion 140, which provides a passage between the cooling flow gap 138 and the collection channel 144. For example, the respective inlet portions 140 may each extend directly from the impact plate 136 to the collection conduit 142, such that they fluidly connect the cooling flow gap 138 directly to the respective collection channel 144.

[0080] Figure 9 A plan view is shown along the radial direction R of the cooling insert 400, which is isolated from the two impact panels 131 and other components of the integrated burner nozzle. (See diagram) Figure 9 As shown, impact panel 131 may represent either or both of outer impact panel 130 and / or inner impact panel 134. In many embodiments, each impact panel 130 may be coupled to a low-pressure inlet 408 of cooling insert 400. In a particular embodiment, each collection conduit 142 may be coupled to a low-pressure inlet 408 via a connecting conduit 180. In some embodiments (not shown), collection conduits 142 may be directly coupled to a corresponding low-pressure inlet 408 of cooling insert 400. As detailed below, the low-pressure inlet 408 of cooling insert 400 may be in direct fluid communication with collection passage 406, and thus in fluid communication with suction-side fuel injector 161. In this way, collection conduits 142 advantageously provide a pathway for post-impact air 154 to travel to the fuel injector, where they can be used to generate combustion gases within auxiliary combustion zone 104.

[0081] In many embodiments, the impact panel 130 may be a single body that extends continuously from the front end to the rear end. However, in exemplary embodiments, such as Figure 9 As shown, the impact panel 130 may include multiple panel segments 182 connected to each other. For example, in many embodiments, the impact panel 130 may include two panel segments 182, such as a front segment 184 and a rear segment 186 connected together. In other embodiments, the impact panel may include three or more segments, such as a front segment 184, a middle segment 185, and a rear segment. In such embodiments, the front segment 184 and the rear segment 186 may each be independently connected to the middle segment 185, as shown. Dividing the impact panel 130 into panel segments 182 advantageously allows for the manufacture of a larger number of impact panels 130 at once, such as through additive manufacturing, which can save on production costs.

[0082] like Figure 11 As shown by the hidden lines, the inlet portion 140 of each panel segment 182 may further define an elongated slot opening 188 through the corresponding impact plate 136, which allows post-impact air 154 to flow from the cooling gap into the collection conduit 142. In some embodiments (not shown), the elongated slot opening 188 may be continuous between panel segments 182.

[0083] In various implementation schemes, such as Figure 9 As shown, each collection conduit 142 may converge in cross-section from a front end 190 to a rear end 192, i.e., converge in the axial direction A. More specifically, the sidewalls 141 of the collection conduits 142 may converge toward each other from the front end 190 to the rear end of the impact panel 130, thereby gradually reducing the second width 178 and cross-sectional area of ​​the collection conduits as they extend in the axial direction A. The gradual reduction of the cross-sectional area of ​​the collection conduits 142 from the front end 190 to the rear end 192 of the impact panel 130 can advantageously influence the flow of post-impact air 154 toward the cooling insert 400, i.e., in the direction opposite to the axial direction.

[0084] In operation, the collection conduit 142 receives used cooling air from the cooling flow gap 138. As used herein, the terms "post-impact air" and / or "used cooling air" refer to air that has impacted a surface and thus undergone energy transfer. For example, the used cooling air may have a higher temperature and lower pressure than before impacting the outer surfaces 131, 135, which prevents further cooling within the integrated combustion nozzle. However, the collection conduit 142 advantageously collects the used cooling air and directs it toward one or more fuel injectors (e.g., fuel injection module 117 and / or fuel injectors 160 and 161, or both) for use in the main combustion zone 102 or auxiliary combustion zone 104. In this way, the impact panel 130 effectively utilizes air from the high-pressure chamber 34 by first using the air to cool the bushing sections 106, 108, and then using the air to generate combustion gases that power the turbine section 18.

[0085] In many embodiments, each panel segment 182 can be integrally formed as a single component. That is, each sub-component (e.g., the impact plate 136, the inlet portion 140, the collection conduit 142, and any other sub-components of the panel segment 182) can be manufactured together as a single body. In exemplary embodiments, this can be accomplished using the additive manufacturing system 1000 described herein. However, in other embodiments, other manufacturing techniques, such as casting or other suitable techniques, can be used. In this regard, using additive manufacturing methods, each panel segment 182 of the impact panel 130 can be integrally formed as a single piece of continuous metal, and thus can include fewer sub-components and / or joints compared to existing designs. Integral forming of each panel segment 182 by additive manufacturing can advantageously improve the overall assembly process. For example, integral forming reduces the number of individual parts that must be assembled, thereby reducing the associated time and total assembly cost. Additionally, existing problems such as leakage, joint quality between individual parts, and overall performance can be advantageously reduced. In some embodiments, the entire impact panel 130 can be integrally formed as a single component.

[0086] Figure 10 A cross-sectional view of the panel segment 182 of the impact panel 130 according to an embodiment of the present disclosure is shown along the axial direction A, and Figure 11 A plan view of panel segment 182 along the radial direction R is shown. It should be understood that... Figure 10 and Figure 11 The features of the panel segment 182 shown can be incorporated into any panel segment described herein (such as front segment 184, middle segment 185 and / or rear segment 186).

[0087] like Figure 10 and Figure 11 As shown, panel segment 182 may further include one or more supports 194 that extend between and integrally form with the inlet portion 140, collection conduit 142, and impact plate 136 to provide structural support for them. In various embodiments, each support 194 may be substantially shaped as a flat plate extending between the impact plate 136 and the collection conduit 142. In a particular embodiment, each support 194 may extend from a first end 196 integrally formed with the impact plate 136 to a second end 198 integrally formed with the collection conduit 142. In an exemplary embodiment, the support 194 may be fixedly coupled to panel segment 182; for example, the support 194 may be a separate component welded and / or brazed to panel segment 182. Utilizing the support 194 in this way provides additional structural integrity to the collection conduit 142, which advantageously prevents damage to the impact panel 130 caused by the vibrational forces of the gas turbine 10 during operation.

[0088] In a particular embodiment, each support 194 includes a first side 197 and a second side 199 extending between a first end 196 and a second end 198 of each support 194, i.e., extending between the impact plate 136 and the collection conduit 142. Figure 10 As shown, the first end 196, the second end 198, the first side 197, and the second side 199 can collectively define the periphery of the support 194. In many embodiments, the first side 197 of the support 194 extends along and is integrally formed with one of the sidewalls 150 of the inlet portion 140. In an exemplary embodiment, the second side 199 of the support 194 can be a generally straight line extending from the impact plate 136 at an angle 200.

[0089] For example, in many embodiments, the second side 199 of each support member 194 may form an angle 200 with the impact plate 136 between about 10° and about 75°. In other embodiments, the second side 199 of each support member 194 may form an angle 200 with the impact plate 136 between about 20° and about 65°. In various embodiments, the second side 199 of each support member 194 may form an angle 200 with the impact plate 136 between about 30° and about 55°. In a particular embodiment, the second side 199 of each support member 194 may form an angle 200 with the impact plate 136 between about 40° and about 50°.

[0090] In an exemplary embodiment, the angle 200 of the second side 199 advantageously provides additional structural support to the impact panel 130, thereby preventing vibration damage to the impact panel 130 during operation of the gas turbine 10. Furthermore, the angle 200 of the second side 199 can provide additional structural support to the collection conduit 142 during the additive manufacturing process of the impact panel 130, which advantageously reduces the likelihood of deformation and / or defects in the impact panel 130. For example, when using additive manufacturing system 1000 ( Figure 15 During manufacturing, the angle 200 of the second side 199 discussed herein relative to the impact plate 136 prevents the support 194 from overhanging, i.e., from having excessive thickness variation. As a result, the impact panel 130 (which would be difficult to manufacture by conventional means due to its complex geometry) can be manufactured using the additive manufacturing system 1000 without causing defects or deformation in the part.

[0091] like Figure 11 As shown, each support member 194 can form an angle 202 with the inlet portion 140 (e.g., Figure 11(As shown by the dashed lines in the diagram). More specifically, each support 194 may form an angle 202 with the sidewall 150 of the inlet portion 140. In many embodiments, the angle 202 may be inclined, which advantageously allows the support 194 to extend further along the impact plate 136. However, in other embodiments (not shown), one or more of the supports 194 may be perpendicular to the inlet portion 140.

[0092] In various embodiments, the angle 202 between the sidewall 150 of the inlet portion 140 and the support 194 can be between about 10° and about 90°. In other embodiments, the angle 202 between the sidewall 150 of the inlet portion 140 and the support 194 can be between about 20° and about 70°. In a particular embodiment, the angle 202 between the sidewall 150 of the inlet portion 140 and the support 194 can be between about 30° and about 60°. In many embodiments, the angle 202 between the sidewall 150 of the inlet portion 140 and the support 194 can be between about 40° and about 50°.

[0093] like Figure 11 As shown, panel alignment 182 may further include a central axis 206, which may be generally parallel to the sidewall 150 of inlet portion 140. In many embodiments, when panel portion 182 is mounted in integrated burner 100, central axis 206 may extend coaxially with the axial direction A of gas turbine 10. In other embodiments, when panel portion is mounted in integrated burner nozzle 100, central axis 206 may extend generally parallel to the axial direction A.

[0094] Figure 12 A cross-sectional perspective view of a panel segment 182 according to an embodiment of the present disclosure is shown. The panel segment 182 is extendable along a central axis 206 (…). Figure 11 It extends from the first end 208 to the second end 210. Figure 13 A plan view of an exemplary embodiment of the first end 208 of the panel segment 182 along the central axis 206 is shown, and Figure 14 The second end 210 of the panel segment 182 along the central axis 206 is shown.

[0095] like Figure 13 As shown, the first end 208 of the panel section 182 includes a flange 212 extending from the impact panel. In various embodiments, the flange 212 may be a generally flat plate extending from the first end 208 of the panel section 182. More specifically, the flange 212 may extend at the first end 208 of the panel section 182 perpendicular to and away from the impact plate 136, the inlet portion 140, and the collection conduit 142, in order to define a connection surface 213. Figure 13The connecting surface 213 advantageously allows multiple panel segments 182 to be securely joined together by means such as welding, brazing, or other suitable methods. In many embodiments, the flange 212 also increases the overall rigidity and structural integrity of the panel segments 182, thereby preventing vibration damage to the components that may occur during operation of the gas turbine 10.

[0096] In many embodiments, flange 212 may be integrally formed with panel segment 182, such that collection plate 136, inlet portion 140, collection conduit 142, and flange 212 can be a single piece of continuous metal. In such embodiments, flange 212 may also provide manufacturing advantages. For example, flange 212 generally surrounds features of panel segment 182 and provides additional structural support for collection conduit 142 during additive manufacturing processes.

[0097] like Figure 14 As shown, in some embodiments, the second end 210 of the impact panel 182 may not include the flange 212 integrally formed therewith, as is the case with the first end 208. Figure 14 As shown by the dashed lines, end plate 211 can be attached to and fixedly connected to the second end 210. For example, end plate 211 can be a component completely separate from the impact panel section 182. In many embodiments, end plate 211 can be welded or brazed to the second end 210 after the impact panel section 182 is manufactured. End plate 211, fixedly connected to the second end 210, can have a geometry substantially similar to flange 212, but is a separate component rather than integrally formed. End plate 211 can be used to connect the second end 210 of impact panel section 182 to the first end 208 of an adjacent impact panel section (e.g., ...). Figure 9 (As shown). In an exemplary embodiment, the end plate 211 of the impact panel segment 182 may be fixedly coupled to the flange 212 of an adjacent impact panel segment 182. This coupling of the impact panel segments 182 is advantageous because the end plate 211 and the flange 212 are relatively flat and smooth surfaces, providing easy and error-free welding between them. In other embodiments, both the first end 208 and the second end 210 may include flanges 212, wherein the flange 212 of the first end 208 of the panel segment 182 may be fixedly coupled to the flange 212 of the second end 210 of the adjacent panel segment 182.

[0098] To illustrate examples of additive manufacturing systems and processes, Figure 15 A schematic view / block diagram of an additive manufacturing system 1000 for generating objects 1220 (such as panel segment 182, cooling insert 400 and / or impact cooling device 300 as described herein) is shown. Figure 15This may refer to an additive manufacturing system configured for direct metal laser sintering (DMLS) or direct metal laser melting (DMLM). The additive manufacturing system 1000 manufactures objects, such as object 1220 (which may represent panel segment 182, cooling insert 400, and / or shock cooling device 300 as described herein). For example, object 1220 can be manufactured layer-by-layer by sintering or melting powder material (not shown) using an energy beam 1360 generated by a source (such as laser 1200). Powder to be melted by the energy beam is supplied from a reservoir 1260 and uniformly spread on a build plate 1002 using a coater arm 1160 to hold the powder at a level 1180 and remove excess powder material extending above the powder level 1180 to a waste container 1280. The energy beam 1360 sinters or melts the cross-sectional layers of the constructed object under the control of a galvanometer scanner 1320. The build plate 1002 is lowered, and another layer of powder is spread onto the build plate and the object being built, after which the powder is continuously melted / sintered by a laser 1200. This process is repeated until the object 1220 is entirely constructed from the molten / sintered powder material. The laser 1200 can be controlled by a computer system including a processor and memory. The computer system can determine the scanning pattern for each layer and control the laser 1200 to irradiate the powder material according to the scanning pattern. After the manufacture of the object 1220 is completed, various post-processing procedures can be applied to the object 1220. Post-processing procedures include removing excess powder by, for example, purging or vacuuming. Other post-processing procedures include stress relief processes. Additionally, thermal and chemical post-processing procedures can be used to finish the object 1220.

[0099] Figure 16 This is a flowchart of a set of sequential steps 1602 to 1606 according to an embodiment of the present disclosure, which define a method 1600 for manufacturing an impact panel (such as one of the impact panels 130, 131, 134 described herein). Method 1600 can be performed using an additive manufacturing system (such as additive manufacturing system 1000 described herein or another suitable system). Figure 16 As shown, method 1600 includes step 1602 of irradiating a powder layer in powder bed 1120 to form a molten region. In many embodiments, such as Figure 15 As shown, a powder bed 1120 may be disposed on a build plate 1002 such that a molten region is fixedly attached to the build plate 1002. Method 1600 may include step 1604 of providing a subsequent powder layer on the powder bed 1120 from a first side of the powder bed 1120. Method 1600 further includes step 1606 of repeating steps 1602 and 1604 until an impact panel is formed in the powder bed 1120.

[0100] Figure 17A perspective view of an impact cooling device 300, isolated from and positioned on a build plate 1002, is shown, wherein one of the row of impact members has been removed. As described below, the impact cooling device 300 can be additively manufactured on the build plate 1002, for example, by an additive manufacturing system 1000. Figure 17 An impact cooling device 300 is depicted according to an embodiment of the present disclosure before being removed from the building plate 1002 and installed into the integrated burner nozzle 100.

[0101] like Figure 17 As shown, the impact cooling device 300 can extend from a first end 306 to a second end 308 in a radial direction R that can coincide with the construction direction. In many embodiments, the impact cooling device 300 includes a plurality of impact members 302 arranged in a first row 320 impact members 302 and a second row 322 impact members 302. Each impact member 302 in the first row 320 impact members 302 can extend from a first flange 310 at the first end 306 of the impact cooling device 300 to a corresponding closed end 312 at the second end 308. Similarly, each impact member 302 in the second row 322 impact members 302 can extend from a second flange 311 at the first end 306 of the impact cooling device 300 to a corresponding closed end 312 at the second end 308. In this way, the impact members 302 of the first row 320 and the second row 322 can each be individual components that can move relative to each other during installation into the cavity 126, which advantageously allows the distances between the impact members 302 of the rows 320, 322 and the walls 116, 118 to be set independently of each other.

[0102] In other embodiments, each impact member 302 may be a completely separate component capable of movement relative to the other impact members 302 in the impact cooling device 300. In such embodiments, each impact member 302 may extend from a corresponding flange. In embodiments where each impact member 302 is a separate component, the impact members may be individually installed within the integrated burner nozzle (i.e., one at a time), and each support 356, 358 may be used to ensure an appropriately sized gap between each impact member 302 during both installation and operation of the impact members 302.

[0103] In an exemplary embodiment, each impact member 302 may be a substantially hollow body extending from a corresponding opening 313 defined in flanges 310, 311 to a corresponding closed end 312. Figure 19 In many embodiments, the corresponding solid wall 316 of each impact member 302 may taper toward and connect to the corresponding impact wall 314 at the corresponding closed end 312. Although Figure 17The embodiment shown depicts an impact cooling device 300 with eleven impact cooling members 302, but the impact cooling device 302 may have any number of impact members 302, such as 4, 6, 8, 12, 14 or more. In various embodiments, such as Figure 17 As shown, each of the plurality of impact members 302 may be spaced apart from the directly adjacent impact members 302 to define a gap 172, so that post-impact air 154 flows between the impact members 302 and enters the collection passage 174. Figure 6 In many embodiments, a plurality of impact holes 304 may be defined on each of the plurality of impact members 302.

[0104] Figure 18 An enlarged cross-sectional view of the integrated burner nozzle 100 along the radial direction R is depicted, wherein the impact cooling device 300 is positioned within the cavity 126. (As shown) Figure 18 As shown, the integrated burner nozzle 100 may further include an outward-curving axis 318, which may be defined midway between the pressure sidewall 116 and the suction sidewall 118. For example, the outward-curving axis 318 may be curved and / or contoured to correspond to the curves of the pressure sidewall 116 and the suction sidewall 118. The lateral direction T may be orthogonally defined relative to the outward-curving axis 118. More specifically, the lateral direction T may extend outwardly and perpendicularly from a line tangent to the outward-curving axis 318 at each location along the outward-curving axis 318.

[0105] In a particular embodiment, each of the plurality of impact members 302 includes an impact wall 314 spaced apart from the solid wall 316. In an exemplary embodiment, a plurality of impact holes may be defined on the impact wall 314 to guide pre-impact air 152 toward the inner surfaces 156, 158 of the walls 116, 118. Figure 6 Solid walls 316 may be disposed opposite impact walls 314. In many embodiments, the solid wall 314 of each respective impact member 302 may be located directly outside the outward tilt axis 318 in the lateral direction T, such that the solid walls 316 of the impact members 302 collectively define the boundary of the collection passage 174. As used herein, the term “solid” may refer to one or more impermeable walls such that they do not allow air or other fluids to pass through them. For example, each solid wall 316 may not have any impact holes, openings, or gaps that would allow pre-impact air 152 to escape, in order to ensure that all air is directed toward the inner surfaces 156, 158 of the walls 116, 118 for cooling.

[0106] In a specific implementation, such as Figure 18As shown, the plurality of impact members 302 may include a first row of impact members 320 disposed near the pressure sidewall 116 and a second row of impact members 322 disposed near the suction sidewall 118. For example, the first row of 320 and the second row of 322 impact members may be disposed on opposite sides of the outward tilt axis 318, such that they are spaced apart in the lateral direction T. Figure 18 As shown, the collection passage 174 can be defined between the first row 320 and the second row 322 impact members 302. More specifically, the collection passage 174 can be collectively defined between the solid walls 316 of the first row 320 impact members 302 and the solid walls 316 of the second row 322 impact members 302. Figure 6 As shown and described above, the collection passage 174 can be used to receive post-impact air 154 and direct it toward a fuel injector, such as a suction-side fuel injector 161. Figure 6 ).

[0107] In a particular embodiment, the first row 320 impact members 302 and the second row 322 impact members are diverged from each other from the rear end 324 to the front end 326 of the impact cooling device 300 (i.e., opposite to the direction of the combustion gases in the combustion zones 102, 104). For example, the first row 320 impact members 302 and the second row 322 impact members are diverged from each other in the lateral direction from the rear end 324 to the front end 326 of the impact cooling device 300. In this way, the lateral distance between the first row 320 impact members 302 and the second row 322 impact members 302 can gradually increase from the rear end 324 to the front end 326, thereby affecting the travel of the post-impact air 154 toward the suction-side fuel injector 161.

[0108] like Figure 18 As shown, the impact wall 314 of each corresponding impact member 302 on the first row 320 can be profiled to correspond to a portion of the pressure sidewall 116, such that the impact walls 314 of the first row 320 collectively correspond to the profile of the pressure sidewall 116. Similarly, the profile of the impact wall 314 of each corresponding impact member 302 on the second row 322 can be profiled to correspond to a portion of the suction sidewall 118, such that the impact walls 314 of the second row 322 collectively correspond to the profile of the suction sidewall 118. The profiles of the matching walls 116, 118 advantageously maintain a desired lateral distance from the corresponding walls 116, 118. In many embodiments, the lateral distance between the impact wall 314 and the corresponding walls 116, 118 can be substantially constant.

[0109] In a particular embodiment, each of the plurality of impact members 302 may include a first solid sidewall 328 and a second solid sidewall 330, each extending between an impact wall 314 and a solid wall 316. Figure 18As shown, the first solid sidewall 328 and the second solid sidewall 330 of each impact member 302 may be spaced apart from each other and arranged opposite to each other. In various embodiments, the first solid wall 328 and the second sidewall 330 of each impact member 302 may be substantially parallel to each other in the transverse direction T. Figure 18 As shown, the first solid sidewall 328, second solid wall 330, impact wall 314, and solid wall 316 of each of the plurality of impact members collectively define an internal volume 332 in fluid communication with the high-pressure chamber 34. In an exemplary embodiment, each impact member 302 may define a generally rectangular cross-sectional area. However, in other embodiments (not shown), each impact member 302 may define a cross-sectional area having a circular, rhomboid, triangular, or other suitable cross-sectional shape.

[0110] In a specific implementation, such as Figure 6 , Figure 18 and Figure 20 As shown, gap 172 can be defined between directly adjacent impact members 302, which advantageously provides a path for post-impact air 154 to travel into the collection passage 174. In various embodiments, each gap 172 can be directly defined between a first sidewall 328 of the impact member and a second sidewall 330 of the directly adjacent impact member 302. In this way, each of the plurality of impact members 302 partially defines at least one gap 172. Figure 18 As shown, each gap 172 may be defined at its respective location between a first sidewall 328 of the impact member 302 and a second sidewall 330 of the adjacent impact member 302 in a direction generally parallel to the outward tilt axis 318. In other embodiments (not shown), each impact member 302 may define a rhomboid cross-sectional region. In such embodiments, the first sidewall 328 and the second sidewall 330 may be angled relative to the outward tilt axis, which may advantageously reduce the pressure drop of the impact air.

[0111] Figure 19 A cross-sectional view of a single impact member 302 along the outward tilt axis 318 is depicted. Figure 20 An enlarged cross-sectional view of an impact member 302 in the radial direction R and portions of two adjacent impact members 302 according to an embodiment of the present disclosure is shown. It should be understood that... Figure 19 and Figure 20 The features of the impact member 302 shown can be incorporated into any of the plurality of impact members 302 described herein. In an exemplary embodiment, such as Figure 19 and Figure 20As shown, the impact member 302 may further include a first protrusion 334, a second protrusion 335, and a plurality of lateral supports 346 extending therebetween. In many embodiments, the first protrusion 334 may be disposed on the impact wall 314, the second protrusion 335 may be disposed on the solid wall 316, and the plurality of lateral supports 346 may each extend from the first protrusion 334 through the internal volume 332 to the second protrusion 335. Each of the protrusions 334, 335 may extend from the respective wall 314, 316 toward the axial centerline 336 of the impact member 302. Figure 19 More specifically, the first protrusion 334 may extend directly from the inner surface 338 of the impact wall 314 toward the axial centerline 336. Similarly, the second protrusion 335 may extend directly from the inner surface 340 of the solid wall 316 toward the axial centerline 336. In various embodiments, the first protrusion 334 may extend radially along the entire length of the impact wall 314, for example, between the open end 313 and the closed end 312 of the impact member 302.

[0112] In a specific implementation, such as Figure 20 As shown, each protrusion 334, 335 may include a first portion 342 extending generally perpendicularly between the respective walls 314, 316 and the second portion 344. The second portion 344 of each protrusion 334, 335 may extend generally perpendicularly to the corresponding first portion 342, such that each protrusion 334, 335 defines a T-shaped cross-section. The protrusions 334, 335 advantageously improve the stiffness of each impact member 302, and therefore they improve the overall stiffness of the impact cooling device 300. The increased stiffness of the impact cooling device 300 can prevent damage caused by the vibrational forces of the gas turbine 10 during operation. For example, the protrusions 334, 335 can impart a more desirable natural frequency to the impact cooling device 300 in order to prevent failure of the impact cooling device 300 caused by minor oscillations of the integrated combustion nozzle 100.

[0113] like Figure 19 and Figure 20 As shown, each lateral support 346 may include a first support rod 348 and a second support rod 350, the first support rod and the second support rod intersecting at a point 352 disposed within the internal volume 332 of the impact member 302. Figure 19They intersect at each other. In a particular embodiment, the first support rod 348 and the second support rod 350 of each transverse support 346 may extend between the first protrusion 334 and the second protrusion 335. More specifically, the first support rod 348 and the second support rod 350 of each transverse support 346 may extend directly between the second portion 344 of the first protrusion 334 and the second portion 344 of the second protrusion 335. In other embodiments (not shown), the first support rod 348 and the second support rod 350 of each transverse support may extend directly between the interior of the impact wall and the interior of the solid wall, such that there are no protrusions.

[0114] In many implementations, such Figure 19 As shown, the first support rod 348 and the second support rod may each form an angle 354 inclined (i.e., not parallel or not perpendicular) with respect to the flange 310. For example, in some embodiments, the first support rod 348 and the second support rod 350 may each form an angle 354 with respect to the flange 310 between about 15° and about 75°. In other embodiments, the first support rod 348 and the second support rod 350 may each form an angle 354 with respect to the flange 310 between about 25° and about 65°. In various embodiments, the first support rod 348 and the second support rod 350 may each form an angle 354 with respect to the flange 310 between about 35° and about 55°. In a particular embodiment, the first support rod 348 and the second support rod 350 may each form an angle 354 with respect to the flange 310 between about 40° and about 50°. Angle 354 advantageously provides additional structural integrity and internal support to each impact member 302, which prevents damage due to the vibrational forces of the gas turbine 10. Furthermore, as described below, the angle 354 of the support rods 348, 350 allows the impact member 302 to be additively manufactured without defects or deformation. For example, when additively manufactured layer by layer, such as using the additive manufacturing system 1000 described herein, the angle of the support rods 348, 350 advantageously prevents the lateral support member 346 from overhanging in other unfavorable ways, which could lead to component deformation and / or complete collapse. For example, it may be difficult and / or impossible to manufacture support rods that extend vertically across the impact member 302 using an additive manufacturing system. Therefore, the angle 354 between the support rods 348, 350 and the flange 310 is advantageous.

[0115] In many implementations, such Figures 17 to 20As shown, the impact cooling device 300 may further include supports 356, 358 extending from each impact member 302. Supports 356, 358 may be shaped as substantially flat plates extending outwardly from the impact member 302. In many embodiments, the supports may space each impact member 302 away from surrounding surfaces, such as the walls 116, 118 of adjacent impact members 302 and / or the combustion bushing 110. Supports 356, 358 may be configured to hold the impact member 302 at a desired distance from the surrounding surface to optimize impact cooling of the combustion bushing 310 and recirculation of post-impact air 154 into the collection passage 174.

[0116] In a particular embodiment, the support may include a sidewall support 356 and an impact wall support 358. For example... Figure 17 As shown, in many embodiments, at least one sidewall support 356 and at least one impact wall support 358 may be disposed near the flanges 310, 311 on each impact member 302. In various embodiments, at least one sidewall support 356 and at least one impact wall support 358 may be disposed near the closed end 312 of each of the plurality of impact members 302. Arranging the supports 356, 358 near the first end 306 and the second end 308 of the impact cooling device 300 can advantageously provide more uniform support and spacing between adjacent impact members 302 and between the impact members 302 and the walls 116, 118 of the combustion bushing 110.

[0117] In a specific implementation, such as Figure 20 As shown, sidewall supports 356 may each extend from a first solid sidewall 328 of an impact member 302 and connect thereto to a second solid sidewall 330 of an adjacent impact member 302. In an exemplary embodiment, the length of the sidewall supports 356 may define the distance of the gap 172 and may connect adjacent impact members 302 together. For example, rows of impact members 302 (e.g., first row 320 and / or second row 322) may be connected to adjacent impact members 302 within that row via one or more of the sidewall supports 356. In this way, the sidewall supports 356 serve to maintain sufficient space between the impact members 302. Furthermore, the sidewall supports 356 advantageously prevent the relatively elongated impact members 302 from deforming during the additive manufacturing process by providing additional structural support to the impact cooling device 300.

[0118] In various implementation schemes, such as Figure 18As shown, the impact wall support 358 can be used to maintain sufficient space between the impact member 302 and one of the walls 116, 118 of the combustion bushing 110. For example, in an exemplary embodiment, the impact wall support 358 may extend from the impact wall 314 and contact one of the walls 116, 118 of the combustion bushing 310, which may be one of the first sidewall 116 or the second sidewall 118 of the combustion bushing 310. For example, unlike the sidewall support 356, the impact wall supports 358 are not connected at both ends, but they are integrally formed with the impact wall 314 at one end and contact the inner surface of the pressure sidewall 116 or the suction sidewall 118 once the impact cooling device 300 is installed in the combustion bushing 110. In this way, the impact wall support 358 can be removably connected to the combustion bushing 110. In an exemplary embodiment, the length of the sidewall support 358 can be set as the distance between the impact wall 314 and the wall 116 or 118 of the combustion bushing 310.

[0119] Figure 21 and Figure 22 An enlarged view of an impact wall support 358 according to an embodiment of the present disclosure is shown, extending from the impact wall 314 of the impact member 302 to one of the walls 116, 118 of the combustion bushing 310 (shown in dashed lines). More specifically, Figure 20 An impact wall support 358 is shown immediately following, for example, manufacturing by additive manufacturing system 1000 but prior to any post-machining. In many embodiments, each impact wall support may be manufactured with excess material or length 360, as shown by the extension of support 358 beyond the length 360 of wall 116 or 118. Figure 21 As shown, excess material or length 360 of the support 358 can be removed to maintain the desired tolerance between the impact wall 314 and the walls 116, 118, thereby achieving optimal cooling performance.

[0120] although Figure 22 An exemplary embodiment of the impact wall support 358 of the impact cooling device 300 is shown, but Figure 21 This may represent various other supports disclosed herein (such as supports mounted on the impact panel 130 and / or supports mounted on the cooling insert 400).

[0121] In a particular embodiment, each row of impact members 320, 322 in the impact cooling device 300 can be integrally formed as a single component. That is, each sub-component (e.g., flanges 310, 311, impact member 302, first protrusion 334, second protrusion 335, multiple lateral supports 346, supports 356, 358, and any other sub-component of each row of impact members 302, 320, 322) can be manufactured together as a single body. In an exemplary embodiment, this can be accomplished using the additive manufacturing system 1000 described herein. However, in other embodiments, other manufacturing techniques, such as casting or other suitable techniques, can be used. In this regard, using an additive manufacturing method, each row of impact members 320, 322 can be integrally formed as a single piece of continuous metal, and thus can include fewer sub-components and / or joints compared to existing designs. Integrating each row of impact members 320, 322 into one row using additive manufacturing can advantageously improve the overall assembly process. For example, integral forming reduces the number of individual parts that must be assembled, thereby reducing the associated time and total assembly cost. Additionally, it can advantageously reduce existing problems such as leakage, joint quality between individual parts, and overall performance. In some embodiments (not shown), the entire impact cooling device 300 may be integrally formed as a single component. In such embodiments, the impact cooling device may have a single flange, rather than a first flange 310 and a second flange 311, from which all impact members 302 extend.

[0122] Figure 23 A flowchart is provided for a set of sequential steps 2302 to 2306 according to an embodiment of the invention, which define a method 2300 for manufacturing an impact cooling device 300. Method 2300 can be performed using an additive manufacturing system (such as the additive manufacturing system 1000 described herein or another suitable system). Figure 23 As shown, method 2300 includes step 2302 of irradiating a powder layer in powder bed 1120 to form a molten region. In many embodiments, such as Figure 15 As shown, a powder bed may be disposed on a build plate 1002 such that a molten region is fixedly attached to the build plate 1002. Method 2300 may include step 2304 of providing a subsequent powder layer on the powder bed 1120 from a first side of the powder bed 1120. Method 2300 further includes step 2306 of repeating steps 2302 and 2304 until the impact cooling device 300 is formed in the powder bed 1120.

[0123] Figure 24 A perspective view of a cooling insert 400 according to an embodiment of the present disclosure is shown, which is isolated from other components of the integrated burner nozzle 100. Figure 24As shown, the cooling insert 400 may extend between a first end 410 and a second end 412. In many embodiments, the cooling insert 400 includes a flange 414 that extends at the first end 410 of the cooling insert 400 between and generally surrounds the walls 402, 403. In many embodiments, the flange 414 may define one or more openings that provide fluid communication between one or more of the cooling insert 400, the high-pressure chamber 34, and / or the impact panel 130 described herein. In various embodiments, the flange 414 may connect the cooling insert 400 to one of the inner bushing section 106 or the outer bushing section 108. As discussed in more detail below, the flange 414 may define both a first opening end 418 and a second opening end 428 to provide fluid communication between the high-pressure chamber 34 and the first and second walls of the cooling insert 400. In this way, the first opening end 418 and the second opening end 428 defined within the flange 414 can serve as high-pressure air inlets. In many embodiments, the cooling insert 400 may further include a low-pressure inlet 408 defined within a flange 414. For example... Figure 6 and Figure 9 As shown in the best embodiment, the low-pressure inlet 408 provides fluid communication between the collection conduit 142 of the impact panel 130 and the collection passage 406 of the cooling insert 400. Figure 9 ).

[0124] Figure 25 A cross-sectional view of the cooling insert 400 according to an embodiment of the present disclosure is shown along the axial direction A. Figure 26 A cross-sectional view along the radial direction R is shown, and Figure 27 A cross-sectional view of the cooling insert 400 along the circumferential direction C is shown. (See figure) Figure 25 As shown, the cooling insert 400 may include an axial centerline 401 extending between the walls 402, 403 of the cooling insert. In an exemplary embodiment, when the cooling insert 400 is installed in the integrated burner nozzle 100, the axial centerline 401 may coincide with the radial direction R of the gas turbine 10.

[0125] like Figure 25As shown, the cooling insert 400 may include a first wall 402 defining a first channel 416 therein. As shown, the first wall 402 may extend generally radially from a first open end 418 defined within a flange 414 to a first closed end 420. In this way, the first wall 402 may be a substantially hollow body that receives air from the high-pressure chamber 34 via the first open end 418 defined in the flange 414. In a particular embodiment, the first wall 410 includes a first impact side 422 spaced apart from a first solid side 424. As shown, the first channel 416 may be directly defined between the first impact side 422 and the first solid side 424. In various embodiments, the first impact side 422 may define a first plurality of impact holes 404 configured to guide air from the first channel 416 toward a first sidewall (e.g., pressure sidewall 116) of the combustion bushing 110. Figure 5 In many embodiments, the size and orientation of the first plurality of impact orifices 404 may be configured to guide pre-impact air 152 in the form of a discrete jet of air to impact the inner surface 156 of the pressure sidewall 116. The discrete air jets impact (or impinge) the inner surface 156 and create a thin air boundary layer on the inner surface 156, which allows for optimal heat transfer between the pressure sidewall 116 and the air.

[0126] Similarly, the cooling insert 400 may further include a second wall 403 spaced apart from the first wall 402. In many embodiments, the second wall 403 may define a second channel 426 therein. As shown, the first wall 402 may extend generally radially from a second open end 428 defined within a flange 414 to a second closed end 430. In this way, the second wall 403 may be a substantially hollow body that receives air from the high-pressure chamber 34 via the second open end 428 defined in the flange 414. In a particular embodiment, the second wall 403 includes a second impact side 432 spaced apart from a second solid side 434. As shown, the second channel 426 may be directly defined between the second impact side 432 and the second solid side 434. In various embodiments, the second impact side 432 may define a second plurality of impact holes 405 that may be configured to guide air from the second channel 426 toward a second sidewall (e.g., suction sidewall 118) of the combustion bushing 110. Figure 5 In many embodiments, the size and orientation of the second plurality of impact orifices 405 can be configured to guide pre-impact air 152 in the form of a discrete jet of air to impact the inner surface 158 of the suction sidewall 118. Discrete air jets impact (or impinge) the inner surface 158. Figure 6 And a thin air boundary layer is created on the inner surface 158, which allows for optimal heat transfer between the suction sidewall 118 and the air.

[0127] As used herein, the term "solid" may refer to one or more impermeable walls that do not allow air or other fluids to pass through them. For example, the first solid side 424 and the second solid side 434 may not have any impact holes, openings, or gaps that would allow pre-impact air 152 to escape, in order to ensure that all air is directed toward the inner surfaces 156, 158 of the walls 116, 118 for cooling.

[0128] like Figure 25 As shown, the first wall 402 may include a first row 436 of support members 438 extending between the first impact side 422 and the first solid side 424. For example, in some embodiments, each support member 438 may extend directly between the first impact side 422 and the first solid side 424, thereby advantageously providing additional structural integrity to the first wall 402. Figure 25 As shown, each of the first row 436 support members 438 may form an angle 440 with respect to the first solid sidewall 424, which allows the support members 438 to be manufactured together with the first wall 402 via an additive manufacturing system (such as the additive manufacturing system 1000 described herein). For example, in many embodiments, each of the first row 436 support members 438 may form an angle 440 with respect to the first solid sidewall 424 between about 10° and about 80°. In other embodiments, each of the first row 436 support members 438 may form an angle 440 with respect to the first solid sidewall 424 between about 20° and about 70°. In a particular embodiment, each of the first row 436 support members 438 may form an angle 440 with respect to the first solid sidewall 424 between about 30° and about 60°. In many embodiments, each of the first row of 436 support members 438 may be formed with the first solid sidewall 424 at an angle 440 between about 40° and about 50°.

[0129] Similarly, the second wall 403 may include a second row of 442 supports 444 extending between the second impact side 432 and the second solid side 434. For example, in some embodiments, each support 444 in the second row of 442 supports 444 may extend directly between the second impact side 432 and the second solid side 434, thereby advantageously providing additional structural integrity to the second wall 403. Figure 25As shown, each of the second row 442 support members 444 may form an angle 446 with respect to the second solid sidewall 434, which allows the support members 444 to be manufactured together with the second wall 403 via an additive manufacturing system (such as the additive manufacturing system 1000 described herein). For example, in many embodiments, each of the second row 442 support members 444 may form an angle 446 with respect to the second solid sidewall 434 between about 10° and about 80°. In other embodiments, each of the second row 442 support members 444 may form an angle 446 with respect to the second solid sidewall 434 between about 20° and about 70°. In a particular embodiment, each of the second row 442 support members 444 may form an angle 446 with respect to the second solid sidewall 434 between about 30° and about 60°. In many embodiments, each of the second row 442 support members 444 may be formed with the second solid sidewall 434 at an angle 446 between about 40° and about 50°.

[0130] The tilt angles 440 and 446 of the supports 438 and 444 allow the walls 402 and 403 to be additively manufactured with minimal defects or deformation, or without defects or deformation. For example, when additively manufacturing layer by layer, such as using the additive manufacturing system 1000 described herein, the tilt angles 440 and 446 of the supports 438 and 444 advantageously prevent the supports 438 and 444 from overhanging in other unfavorable ways, which could lead to component deformation and / or complete collapse. For example, manufacturing supports that extend vertically across impacts using an additive manufacturing system may be difficult and / or impossible. Therefore, the tilt angles 440 and 446 between the supports 438 and 444 and the solid walls 424 and 434 are advantageous.

[0131] like Figure 26 As shown, the first impact side 422 may include a first profile corresponding to a first wall (e.g., pressure sidewall 116). Similarly, in many embodiments, the second impact side may include a second profile corresponding to a second wall (e.g., suction sidewall 116). In this way, impact sides 422, 432 may each maintain a constant distance from the respective sidewalls 116, 118 in the axial direction A, which optimizes impact cooling thereto. As used herein, profiles “corresponding” to each other may refer to two or more walls or surfaces that each have matching or substantially the same curvature in one or more directions.

[0132] In many implementations, such Figure 26As shown, as they extend in the axial direction A, the first impact side 422 can diverge away from the first solid wall 424. Similarly, as they extend in the axial direction A, the second impact side 432 can diverge away from the second solid wall 434. More specifically, the first wall 402 may include a first parallel portion 448 and a first diverging portion 450. The first parallel portion 448 of the first wall 402 may be located close to the front end of the cooling insert 400. Figure 26 As shown, in the first parallel portion 448, the first impact side 422 may be substantially parallel to the first solid side 424. A first diverging portion 450 of the first wall 402 may extend continuously from the first parallel portion 448. In the first diverging portions 450, as they extend in the axial direction A, the first impact side 422 may gradually diverge away from the first solid wall 424, causing the gap between the walls to gradually increase in the axial direction A. Similarly, the second wall 403 may include a second parallel portion 452 and a second diverging portion 454. The second parallel portion 452 of the second wall 403 may be located close to the front end of the cooling insert 400. Figure 26 As shown, in the second parallel portion 452, the second impact side 432 may be substantially parallel to the second solid side 434. The second diverging portion 454 of the second wall 403 may extend continuously from the second parallel portion 452. In many embodiments, in the second diverging portions 452, as they extend in the axial direction A, the second impact side 432 may gradually diverge away from the second solid wall 434, such that the gap between the walls gradually increases in the axial direction A.

[0133] In certain embodiments, the collection passage 406 may be defined between a first solid side 424 and a second solid side 434. For example, in several embodiments, the first solid side 424 and the second solid side 434 may be spaced apart from each other, such that the collection passage 406 is defined between them. In many embodiments, the first solid side 424 and the second solid side 434 may each be a substantially flat plate extending parallel to each other in both the axial direction A and the radial direction R. The collection passage 406 may receive low-pressure air (as opposed to high-pressure pre-impact air) from one or more sources and direct the low-pressure air to fuel injectors 160, 161 for use in the auxiliary combustion zone 104. For example, the collection passage 406 may receive a first low-pressure air source from one or more of the collection conduits 142 of the impact panel 130, which is coupled to the cooling insert 400 via a low-pressure inlet 408 defined within the flange 414. Figure 6 As shown, another low-pressure air source for collecting passage 406 can be post-impact air 154, which has left the impact side and impacted the walls 116, 118.

[0134] like Figures 24 to 27As commonly shown, one or more guide vanes 456 may extend between a first solid side 424 and a second solid side 434 to direct low-pressure air toward fuel injectors 160, 161. In various embodiments, each guide vane 456 may extend directly between the first solid side 424 and the second solid side 434, thereby connecting a first wall 402 of the cooling insert 400 to a second wall 403 of the cooling insert 400. In a particular embodiment, the guide vane 456 may be disposed within a collection passage 406 such that low-pressure air may travel along the guide vane 456 toward the fuel injectors 160, 161. In many embodiments, each guide vane 456 may include an arcuate portion 458 and a straight portion 460 extending continuously from each other. The arcuate portion 458 may be disposed near the front end of the cooling insert 400. The straight portion 460 of the guide vane 456 may extend from the arcuate portion 458 toward the rear end of the cooling insert 400. In many embodiments, when the cooling insert is installed in the integrated burner nozzle 100, the straight portion 460 of the guide vane may be substantially parallel to the axial direction A.

[0135] like Figures 24 to 26 Commonly shown, the first impact side may include a first set of supports 462 extending from the first impact side 422 to a first sidewall (e.g., pressure sidewall 116) when the cooling insert 400 is installed within the integrated burner nozzle 100. Similarly, in many embodiments, the second impact side includes a second set of supports 464 extending from the second impact side 432 to a second sidewall (e.g., suction sidewall 118). Each set of supports 462, 464 may be used to maintain sufficient space between the impact sides 422, 432 and one of the walls 116, 118 of the combustion bushing 110. For example, in an exemplary embodiment, the supports may extend from each respective impact side and contact the walls 116, 118 of the combustion bushing 110. For example, the supports are not coupled at both ends, but are integrally formed with the impact sides 422, 432 at one end and contact the inner surface of the pressure sidewall 116 or suction sidewall 118 once the cooling insert 400 is installed into the combustion bushing 110. In this way, supports 462, 464 can be removably attached to the combustion bushing 110. In an exemplary embodiment, the length of supports 462, 464 can be set at the distance of the gap between the impact side and the walls 116, 118 of the combustion bushing 110.

[0136] Figure 28 An enlarged view of two opposing cooling inserts 400 according to an embodiment of this disclosure is shown. More specifically, Figure 25The closed ends 420 of two opposing cooling inserts 400 are shown. In a particular embodiment, each closed end 420 may include an arcuate portion 466 that bends around the cross flame tube 122. In other embodiments (not shown), where the cross flame tube is not pre-defined, the closed ends may extend in a straight line (e.g., in the axial direction A).

[0137] In many embodiments, each cooling insert 400 may be integrally formed as a single component. That is, each sub-component (e.g., first wall 402, second wall 403, flange 414, guide vane 456, supports 462, 464, and any other sub-components of the cooling insert 400) may be manufactured together as a single body. In exemplary embodiments, this can be accomplished using the additive manufacturing system 1000 described herein. However, in other embodiments, other manufacturing techniques, such as casting or other suitable techniques, may be used. In this regard, using additive manufacturing methods, the cooling insert 400 can be integrally formed as a single piece of continuous metal, and thus may include fewer sub-components and / or joints compared to existing designs. Integral forming of the cooling insert 400 by additive manufacturing can advantageously improve the overall assembly process. For example, integral forming reduces the number of individual parts that must be assembled, thereby reducing the associated time and total assembly cost. Additionally, existing problems such as leakage, joint quality between individual parts, and overall performance can be advantageously reduced.

[0138] This written description uses examples to disclose the invention, including the best mode, and also enables any person skilled in the art to practice the invention, including making and using any device or system and performing any combined methods. The patentable scope of the invention is defined by the claims, but may include other examples that would occur to a person skilled in the art. Such other examples are intended to be within the scope of the claims if they include structural elements that are not different from the literal language of the claims, or if they include equivalent structural elements that are not substantially different from the literal language of the claims.

Claims

1. An integrated burner nozzle (100), comprising: A combustion bushing (110) extends radially between an inner bushing section (106) and an outer bushing section (108), the combustion bushing (110) including a front end portion (112), a rear end portion, a first sidewall (116), and a second sidewall (118), the rear end portion (114) of the combustion bushing (110) defining a turbine nozzle (120), the combustion bushing (110) defining a cavity in front of the turbine nozzle (120), wherein the cavity extends between the first sidewall (116) and the second sidewall (118), wherein a first rib and a second rib extend from one of the first sidewall or the second sidewall and within the cavity, the first rib and the second rib being axially spaced apart such that the cavity is divided into a front cavity portion, an intermediate cavity portion, and a rear cavity portion, and wherein one or more openings are defined in the first rib and the second rib such that the front cavity portion, the intermediate cavity portion, and the rear cavity portion are in fluid communication; A fuel injector having an inlet disposed within the intermediate cavity portion, the fuel injector extending through one of the first sidewall or the second sidewall; as well as An impact cooling device (300) is positioned within the rear cavity portion, the impact cooling device (300) comprising: Flange (310, 311); and A plurality of impact members (302) are configured to guide coolant impacts on at least one of a first sidewall (116) and a second sidewall (118). The plurality of impact members include a first row of impact members disposed near the first sidewall and a second row of impact members disposed near the second sidewall. A collection passage is defined between the first and second rows of impact members such that the collection passage receives post-impact air from a gap defined between the plurality of impact members. The inlet of the fuel injector receives the post-impact air from the collection passage. Each of the plurality of impact members (302) extends from a corresponding inlet (313) defined within the flanges (310, 311) to a corresponding closed end (312). A plurality of impact holes (304) are defined on each of the plurality of impact members (302). The first row (320) impact members (302) and the second row (322) impact members (302) are diverging from each other from the rear end to the front end of the impact cooling device (300).

2. The integrated burner nozzle (100) according to claim 1, wherein each of the plurality of impact members (302) includes an impact wall (314) spaced apart from the solid wall (316), and wherein a plurality of impact holes (304) are each defined on the impact wall (314) of each respective impact member (302) of the plurality of impact members (302).

3. The integrated burner nozzle (100) according to claim 2, wherein the impact wall (314) of each impact member (302) is profiled to correspond to one of the first sidewall (116) or the second sidewall (118) of the combustion bushing (110).

4. The integrated burner nozzle (100) according to claim 2, wherein each of the plurality of impact members (302) includes a first solid sidewall (328) and a second solid sidewall (330), and wherein the first solid sidewall (328) and the second solid sidewall (330) each extend between the impact wall (314) and the solid wall (316).

5. The integrated burner nozzle (100) according to claim 4, wherein the impact wall (314), the first solid sidewall (328), the second solid sidewall (330) and the solid wall (316) of each of the plurality of impact members (302) collectively define the internal volume.

6. The integrated burner nozzle (100) according to claim 1, wherein each of the plurality of impact members (302) is spaced apart from the adjacent impact member.

7. A turbine, comprising: compressor; A compressor discharge housing, wherein the compressor discharge housing is disposed downstream of the compressor; A turbine is disposed downstream of the compressor discharge housing; An annular combustion system, disposed within the compressor discharge housing, includes a plurality of integrated burner nozzles (100) arranged in an annular array around the axial centerline of the turbine, wherein each integrated burner nozzle (100) includes: A combustion bushing (110) extends radially between an inner bushing section (106) and an outer bushing section (108), the combustion bushing (110) including a front end portion (112), a rear end portion, a first sidewall (116), and a second sidewall (118), the rear end portion (114) of the combustion bushing (110) defining a turbine nozzle (120), the combustion bushing (110) defining a cavity in front of the turbine nozzle (120), wherein the cavity extends between the first sidewall (116) and the second sidewall (118), wherein a first rib and a second rib extend from one of the first sidewall or the second sidewall and within the cavity, the first rib and the second rib being axially spaced apart such that the cavity is divided into a front cavity portion, an intermediate cavity portion, and a rear cavity portion, and wherein one or more openings are defined in the first rib and the second rib such that the front cavity portion, the intermediate cavity portion, and the rear cavity portion are in fluid communication; A fuel injector having an inlet disposed within the intermediate cavity portion, the fuel injector extending through one of the first sidewall or the second sidewall; and An impact cooling device (300) is positioned within the rear cavity portion, the impact cooling device (300) comprising: Flanges (310, 311); and A plurality of impact members (302) are configured to guide coolant impacts on at least one of a first sidewall (116) and a second sidewall (118). The plurality of impact members include a first row of impact members disposed near the first sidewall and a second row of impact members disposed near the second sidewall. A collection passage is defined between the first and second rows of impact members such that the collection passage receives post-impact air from a gap defined between the plurality of impact members. The inlet of the fuel injector receives the post-impact air from the collection passage. Each of the plurality of impact members (302) extends from a corresponding inlet (313) defined within the flanges (310, 311) to a corresponding closed end (312). A plurality of impact holes (304) are defined on each of the plurality of impact members (302). The first row (320) impact members (302) and the second row (322) impact members (302) are diverging from each other from the rear end to the front end of the impact cooling device (300).

8. The turbine of claim 7, wherein each of the plurality of impact members (302) includes an impact wall (314) spaced apart from the solid wall (316), and wherein a plurality of impact holes (304) are each defined on the impact wall (314) of each respective impact member (302) of the plurality of impact members (302).

9. The turbine according to claim 8, wherein the impact wall (314) of each impact member (302) is profiled to correspond to one of the first sidewall (116) or the second sidewall (118) of the combustion bushing (110).

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