Additive manufactured primary combustor zone chute turbulators for enhance fuel delivery

Abstract

A gas turbine engine combustor (10) has a fuel manifold configured (14) to deliver fuel to a plurality of fuel injectors (16) and a combustion air manifold (18) configured to deliver combustion air to a plurality of dilution chutes (20). Each of the plurality of fuel injectors (16) is configured to deliver fuel to a corresponding one of the plurality of dilution chutes (20). Each of the plurality of dilution chutes (20) further includes dilution chute walls (22) and a plurality of dilution chute turbulators (24) formed on the dilution chute walls (22). The dilution chute turbulators (24) are configured to create turbulence within the dilution chute (20) when the dilution chute (20) is in operation to enhance fuel atomization and mixing and disrupt formation of fuel films on the dilution chute walls (22).

Description

TECHNICAL FIELD

[0001] The present disclosure relates generally to a gas turbine engine combustor and, more particularly, an additive manufactured (AM) gas turbine engine combustor with unitized, monolithic fuel injectors and dilution chutes.BACKGROUND

[0002] Fuel delivery for AM combustors can be challenged with the lack of post processing capability that results in fuel delivery structures that do not sufficiently atomize fuel. Insufficiently atomized / delivered fuel can result in degraded combustor efficiency, possibly leading to uneven thermal stresses and erosion of turbine nozzle vanes downstream of the combustor, and limit the operability (e.g., relight capability, lean blow out characteristics, etc.) of the combustor at high altitude operation.SUMMARY

[0003] One aspect of this disclosure is directed to a gas turbine engine combustor having a fuel manifold configured to deliver fuel to a plurality of fuel injectors and a combustion air manifold configured to deliver combustion air to a plurality of dilution chutes. Each of the plurality of fuel injectors is configured to deliver fuel to a corresponding one of the plurality of dilution chutes. Each of the plurality of dilution chutes further includes dilution chute walls and a plurality of dilution chute turbulators formed on the dilution chute walls. The dilution chute turbulators are configured to create turbulence within the dilution chute when the dilution chute is in operation to enhance fuel atomization and mixing and disrupt formation of fuel films on the dilution chute walls.

[0004] Another aspect of this disclosure is directed to a method of directing fuel to a gas turbine engine combustor that includes delivering, through a fuel manifold, fuel to a plurality of fuel injectors; delivering, through a combustion air manifold, combustion air to a plurality of dilution chutes; delivering, through each of the plurality of fuel injectors, fuel to a corresponding one of the plurality of dilution chutes to cause the combustion air to mix with the fuel in the corresponding one of the plurality of dilution chutes for form an air / fuel mixture; delivering the air / fuel mixture into a primary combustion zone of the combustor; and combusting the air / fuel mixture in the primary combustion zone. Each of the plurality of dilution chutes further comprises dilution chute walls and a plurality of dilution chute turbulators formed on the dilution chute walls. The dilution chute turbulators are configured to create turbulence within the dilution chute to enhance fuel atomization and mixing and disrupt formation of fuel films on the dilution chute walls.

[0005] Another aspect of this disclosure is directed to a method of forming a gas turbine engine combustor that includes forming a fuel manifold, a plurality of fuel injectors, a combustion air manifold, a plurality of dilution chutes, and a plurality of dilution chute turbulators using a unitary, monolithic structure using additive manufacturing (AM) technique. The fuel manifold is configured to deliver fuel to a plurality of fuel injectors. The combustion air manifold configured to deliver combustion air to a plurality of dilution chutes. Each of the plurality of fuel injectors is configured to deliver fuel to a corresponding one of the plurality of dilution chutes. Each of the plurality of dilution chutes further includes dilution chute walls and a plurality of dilution chute turbulators formed on the dilution chute walls, wherein the dilution chute turbulators are configured to create turbulence within the dilution chute when the dilution chute is in operation to enhance fuel atomization and mixing and disrupt formation of fuel films on the dilution chute walls.BRIEF DESCRIPTION OF THE DRAWINGS

[0006] Fig. 1A is a schematic of a cross-sectional view of a baseline gas turbine engine combustor. Fig. 1B is an enlarged, cross-sectional view of a fuel injector and dilution chute for Fig. 1A. Fig. 1C is another cross-sectional view of the baseline fuel injector and dilution chute of Fig. 1B. Fig. 2A is a cross-sectional view of a fuel injector and dilution chute including turbulators. Fig. 2B is another cross-sectional of the fuel injector and dilution chute including turbulators of Fig. 2A showing the additive manufacturing build direction. Fig. 3 is a cross-sectional view of the turbulators of Figs. 2A and 2B clocking around an inner bore of the dilution chute. Fig. 4A is a side view of a turbulator of Figs. 2A and 2B. Fig. 4B is a side view of an alternate configuration turbulator. DETAILED DESCRIPTION

[0007] Small gas turbine engines are useful for a number of applications for which small size, high altitude relight capability, improved operability and lean blow out characteristics, and good operational life are desirable. In addition, it is often desirable that significant portions of such gas turbine engines can be made using additive manufacturing (AM) processes. Fuel delivery for AM-built unitized, monolithic gas turbine engines can be challenged by limited post processing capability compatible with small features and tight tolerances. As a result, features such as fuel injectors and delivery chutes can deliver poorly atomized and mixed fuel that degrades combustor efficiency. In some cases, the challenges with delivering well atomized and mixed fuel can lead to uneven thermal stresses in the combustor and erosion of turbine nozzle vanes downstream of the combustor. In addition to limiting gas turbine engine operational life, poorly atomized and mixed fuel can limit high altitude relight capability and lean blow out characteristics.

[0008] The combustor fuel delivery and mixing system that is the subject of this disclosure includes features that address certain shortcomings of previous small gas turbine engine designs. As discussed in more detail below, AM dilution chute turbulators create a region of higher turbulence (due to the turbulators) and enhance fuel atomization and mixing as fuel is delivered from a manifold through a fuel injector. In one example, the AM dilution chute turbulators can be small features positioned on the inner bore of the primary zone dilution chute. The AM dilution chute turbulators can be distributed evenly or randomly and can be located in regions where the features can be built up using AM techniques without support structure.

[0009] Fig. 1A is a schematic of a cross-sectional view of a baseline gas turbine engine combustor 10. Fig. 1B is an enlarged, cross-sectional view of a fuel injector 16 and dilution chute 20. Fig. 1C is another cross-sectional view of the baseline fuel injector 16 and dilution chute 20 of Fig. 1B. Figs. 1A, 1B, and 1C will be discussed together.

[0010] As shown in Fig. 1A, gas turbine engine combustor 10 defines a primary combustion zone 12. A fuel manifold 14 delivers fuel into a plurality fuel injectors 16 that in turn deliver fuel into a plurality of dilution chutes 20 where the fuel mixes with air from a combustion air manifold 18 to form an air / fuel mixture. The air / fuel mixture exits the plurality of dilution chutes 20 and flows into the primary combustion zone 12 where it is ignited and burned to provide energy to drive the gas turbine engine. Figs. 1B and 1C show a baseline dilution chute 20 that includes smooth dilution chute walls 22. In such a design, fuel entering the dilution chute 20 through fuel injector 16 can form a film along the dilution chute walls 22 and not mix well with air entering the dilution chute 20 from the combustion air manifold 18. As a result, fuel in the dilution chute 20 may not be as well atomized and mixed with air as desired.

[0011] Figs. 2A and 2B show a dilution chute 20' with dilution chute walls 22' that include a plurality of dilution chute turbulators 24 as described above. The dilution chute turbulators 24 shown in Figs. 2A and 2B have a tetrahedral shape, but as discussed below can have any other shape deemed appropriate for a particular application (e.g., pentahedral, pyramidal, conical, hemispherical, etc.). The dilution chute turbulators 24 should be configured to disrupt the formation of fuel films on the dilution chute walls 22', which will promote better mixing between the air and fuel flowing through the dilution chute 20' by providing more time and surface area for the air and fuel to mix. A dilution chute 20' can include any number of dilution chute turbulators 24, which can be formed in any orientation or distribution on the dilution chute walls 22'. Similarly, the dilution chute turbulators 24 can formed with any dimensions deemed appropriate for a particular application. For example, each of the characterizing dimensions of the dilution chute turbulators 24 (e.g., height, width, etc.) can be on the order of 0.050 inch (1.27 mm) (e.g., between 0.025 inch [0.64 mm] to 0.075 inch [1.91 mm]) or any other dimension deemed appropriate. In selecting the shape, orientation, distribution, and dimensions for the dilution chute turbulators 24, the designer can consider tradeoffs between the benefits of including the dilution chute turbulators 24 in the dilution chute 20' design and the associated decrease in available cross-sectional flow area through the dilution chute 20'.

[0012] Consistent with the use of AM techniques to form the combustor and associated features, including the fuel injector 16' and the dilution chute 20', the dilution chute turbulators 24 can also be made using AM techniques as part of the same AM build campaign used to build the rest of the combustor and associate features. Any suitable AM technique, including but not limited to laser powder bed fusion (PBF-LB), electron beam powder bed fusion (PBF-EB), and other AM techniques, can be used to form the dilution chute turbulators 24 on the dilution chute walls 22'. The shape of the dilution chute turbulators 24 can be distributed evenly or randomly and can be located in regions where the features can be built up using AM techniques without support structure. Similarly, the dilution chute turbulators 24 should be formed from the same material used to form the combustor and associated features, including the fuel injector 16' and the dilution chute 20'. For example, any material appropriate for forming the combustor and associated features, including the fuel injector 16' and the dilution chute 20', such as a high temperature capable alloy (e.g., a nickel superalloy, copper, copper alloy, etc.) or any other appropriate material can be used to form the dilution chute turbulators 24. Fig. 2B shows one option for build direction for the fuel injector 16', the dilution chute 20', and the dilution chute turbulators 24.

[0013] Fig. 3 is a cross-sectional view of the dilution chute turbulators 24, clocking around an inner bore of the dilution chute 20'. The clocking of the dilution chute turbulators 24 can be selected along with their shape, orientation, distribution, and dimensions to avoid the need for support structures during an AM build process. Figs. 4A and 4B show two alternatives for the shape of the dilution chute turbulators 24. Fig. 4A shows a dilution chute turbulator 24 having a triangular (e.g., tetrahedral) cross-section. Fig. 4B shows a dilution chute turbulator 24 having a curved structure configured to conform with a curved dilution chute wall 22'. A person of ordinary skill will recognize that many other suitable shapes can be used for the dilution chute turbulators 24 (e.g., pentahedral, pyramidal, conical, hemispherical, or other shapes) , depending on the particular application and configuration of the associated dilution chute wall 22',

[0014] The combustor fuel delivery and mixing system that is the subject of this disclosure includes a plurality of dilution chute turbulators 24 to create a region of higher turbulence (due to the turbulators) in the associate dilution chute 20' and enhance fuel atomization and mixing as fuel is delivered from a manifold 14' through a fuel injector 18'. Discussion of Possible Embodiments

[0015] The following are non-exclusive descriptions of possible embodiments of the present invention.

[0016] One aspect of this disclosure is directed to a gas turbine engine combustor having a fuel manifold configured to deliver fuel to a plurality of fuel injectors and a combustion air manifold configured to deliver combustion air to a plurality of dilution chutes. Each of the plurality of fuel injectors is configured to deliver fuel to a corresponding one of the plurality of dilution chutes. Each of the plurality of dilution chutes further includes dilution chute walls and a plurality of dilution chute turbulators formed on the dilution chute walls. The dilution chute turbulators are configured to create turbulence within the dilution chute when the dilution chute is in operation to enhance fuel atomization and mixing and disrupt formation of fuel films on the dilution chute walls.

[0017] The gas turbine engine of the preceding paragraph can optionally include, additionally and / or alternatively, any one or more of the following features, configurations and / or additional elements:

[0018] The gas turbine engine of the preceding paragraph, wherein the fuel manifold, plurality of fuel injectors, combustion air manifold, plurality of dilution chutes, and plurality of dilution chute turbulators are formed as a unitary, monolithic structure using an additive manufacturing (AM) technique.

[0019] The gas turbine engine of the preceding paragraph, wherein the fuel manifold, plurality of fuel injectors, combustion air manifold, plurality of dilution chutes, and plurality of dilution chute turbulators are formed from a nickel superalloy, copper, or a copper alloy.

[0020] The gas turbine engine of the preceding paragraph, wherein the AM technique is laser powder bed fusion (PBF-LB) or electron beam powder bed fusion (PBF-EB).

[0021] The gas turbine engine of the preceding paragraph, wherein the plurality of dilution chute turbulators have a tetrahedral, pentahedral, pyramidal, conical, or hemispherical shape.

[0022] The gas turbine engine of the preceding paragraph, wherein the plurality of dilution chute turbulators have characterizing dimensions between 0.025 inch (0.64 mm) to 0.075 inch (1.91 mm).

[0023] A method of directing fuel to a gas turbine engine combustor that includes delivering, through a fuel manifold, fuel to a plurality of fuel injectors; delivering, through a combustion air manifold, combustion air to a plurality of dilution chutes; delivering, through each of the plurality of fuel injectors, fuel to a corresponding one of the plurality of dilution chutes to cause the combustion air to mix with the fuel in the corresponding one of the plurality of dilution chutes for form an air / fuel mixture; delivering the air / fuel mixture into a primary combustion zone of the combustor; and combusting the air / fuel mixture in the primary combustion zone. Each of the plurality of dilution chutes further comprises dilution chute walls and a plurality of dilution chute turbulators formed on the dilution chute walls. The dilution chute turbulators are configured to create turbulence within the dilution chute to enhance fuel atomization and mixing and disrupt formation of fuel films on the dilution chute walls.

[0024] The method of the preceding paragraph can optionally include, additionally and / or alternatively, any one or more of the following features, configurations and / or additional elements:

[0025] The method of the preceding paragraph, wherein the fuel manifold, plurality of fuel injectors, combustion air manifold, plurality of dilution chutes, and plurality of dilution chute turbulators are formed as a unitary, monolithic structure using an additive manufacturing (AM) technique.

[0026] The method of the preceding paragraph, wherein the fuel manifold, plurality of fuel injectors, combustion air manifold, plurality of dilution chutes, and plurality of dilution chute turbulators are formed from a nickel superalloy, copper, or a copper alloy.

[0027] The method of the preceding paragraph, wherein the AM technique is laser powder bed fusion (PBF-LB) or electron beam powder bed fusion (PBF-EB).

[0028] The method of the preceding paragraph, wherein the plurality of dilution chute turbulators have a tetrahedral, pentahedral, pyramidal, conical, or hemispherical shape.

[0029] The method of the preceding paragraph, wherein the plurality of dilution chute turbulators have characterizing dimensions between 0.025 inch (0.64 mm) to 0.075 inch (1.91 mm).

[0030] A method of forming a gas turbine engine combustor that includes forming a fuel manifold, a plurality of fuel injectors, a combustion air manifold, a plurality of dilution chutes, and a plurality of dilution chute turbulators using a unitary, monolithic structure using additive manufacturing (AM) technique. The fuel manifold is configured to deliver fuel to a plurality of fuel injectors. The combustion air manifold configured to deliver combustion air to a plurality of dilution chutes. Each of the plurality of fuel injectors is configured to deliver fuel to a corresponding one of the plurality of dilution chutes. Each of the plurality of dilution chutes further includes dilution chute walls and a plurality of dilution chute turbulators formed on the dilution chute walls, wherein the dilution chute turbulators are configured to create turbulence within the dilution chute when the dilution chute is in operation to enhance fuel atomization and mixing and disrupt formation of fuel films on the dilution chute walls.

[0031] The method of the preceding paragraph can optionally include, additionally and / or alternatively, any one or more of the following features, configurations and / or additional elements:

[0032] The method of the preceding paragraph, wherein the fuel manifold, plurality of fuel injectors, combustion air manifold, plurality of dilution chutes, and plurality of dilution chute turbulators are formed from a nickel superalloy, copper, or a copper alloy.

[0033] The method of the preceding paragraph, wherein the AM technique is laser powder bed fusion (PBF-LB) or electron beam powder bed fusion (PBF-EB).

[0034] The method of the preceding paragraph, wherein the plurality of dilution chute turbulators have a tetrahedral shape.

[0035] The method of the preceding paragraph, wherein the plurality of dilution chute turbulators have characterizing dimensions between 0.025 inch (0.64 mm) to 0.075 inch (1.91 mm).

[0036] While the invention has been described with reference to an exemplary embodiment(s), it will be understood by those skilled in the art that various changes may be made and equivalents may be substituted for elements thereof without departing from the scope of the invention. In addition, many modifications may be made to adapt a particular situation or material to the teachings of the invention without departing from the essential scope thereof. Therefore, it is intended that the invention not be limited to the particular embodiment(s) disclosed, but that the invention will include all embodiments falling within the scope of the appended claims.

Claims

1. A gas turbine engine combustor comprising: a fuel manifold configured to deliver fuel to a plurality of fuel injectors; and a combustion air manifold configured to deliver combustion air to a plurality of dilution chutes; wherein each of the plurality of fuel injectors is configured to deliver fuel to a corresponding one of the plurality of dilution chutes; wherein each of the plurality of dilution chutes further comprises: dilution chute walls; and a plurality of dilution chute turbulators formed on the dilution chute walls, wherein the dilution chute turbulators are configured to create turbulence within the dilution chute when the dilution chute is in operation to enhance fuel atomization and mixing and disrupt formation of fuel films on the dilution chute walls.

2. The gas turbine engine combustor of claim 1, wherein the fuel manifold, plurality of fuel injectors, combustion air manifold, plurality of dilution chutes, and plurality of dilution chute turbulators are formed as a unitary, monolithic structure using an additive manufacturing (AM) technique, wherein the AM technique is laser powder bed fusion (PBF-LB) or electron beam powder bed fusion (PBF-EB).

3. The gas turbine engine combustor of claim 1 or 2, wherein the fuel manifold, plurality of fuel injectors, combustion air manifold, plurality of dilution chutes, and plurality of dilution chute turbulators are formed from a nickel superalloy, copper, or a copper alloy.

4. The gas turbine engine of any preceding claim, wherein the plurality of dilution chute turbulators have a tetrahedral, pentahedral, pyramidal, conical, or hemispherical shape.

5. The gas turbine engine of any preceding claim, wherein the plurality of dilution chute turbulators have characterizing dimensions between 0.025 inch (0.64 mm) to 0.075 inch (1.91 mm).

6. A method of directing fuel to a gas turbine engine combustor comprising: delivering, through a fuel manifold, fuel to a plurality of fuel injectors; delivering, through a combustion air manifold, combustion air to a plurality of dilution chutes; delivering, through each of the plurality of fuel injectors, fuel to a corresponding one of the plurality of dilution chutes to cause the combustion air to mix with the fuel in the corresponding one of the plurality of dilution chutes to form an air / fuel mixture; delivering the air / fuel mixture into a primary combustion zone of the combustor; and combusting the air / fuel mixture in the primary combustion zone; wherein each of the plurality of dilution chutes further comprises dilution chute walls and a plurality of dilution chute turbulators formed on the dilution chute walls; wherein the dilution chute turbulators are configured to create turbulence within the dilution chute to enhance fuel atomization and mixing and disrupt formation of fuel films on the dilution chute walls.

7. The method of claim 6, wherein the fuel manifold, plurality of fuel injectors, combustion air manifold, plurality of dilution chutes, and plurality of dilution chute turbulators are formed as a unitary, monolithic structure using an additive manufacturing (AM) technique, wherein the AM technique is laser powder bed fusion (PBF-LB) or electron beam powder bed fusion (PBF-EB).

8. The method of claim 6 or 7, wherein the fuel manifold, plurality of fuel injectors, combustion air manifold, plurality of dilution chutes, and plurality of dilution chute turbulators are formed from a nickel superalloy, copper, or a copper alloy.

9. The method of any of claims 6 to 8, wherein the plurality of dilution chute turbulators have a tetrahedral shape.

10. The method of any of claims 6 to 9, wherein the plurality of dilution chute turbulators have characterizing dimensions between 0.025 inch (0.64 mm) to 0.075 inch (1.91 mm).

11. A method of forming the gas turbine engine combustor of claim 1 comprising: forming the fuel manifold, the plurality of fuel injectors, the combustion air manifold, the plurality of dilution chutes, and the plurality of dilution chute turbulators using a unitary, monolithic structure using additive manufacturing (AM) technique, wherein the AM technique is laser powder bed fusion (PBF-LB) or electron beam powder bed fusion (PBF-EB).

12. The method of claim 11, wherein the fuel manifold, plurality of fuel injectors, combustion air manifold, plurality of dilution chutes, and plurality of dilution chute turbulators are formed from a nickel superalloy, copper, or a copper alloy.

13. The method of any of claims 11 or 12, wherein the plurality of dilution chute turbulators have a tetrahedral, pentahedral, pyramidal, conical, or hemispherical shape.

14. The method of any of claims 11 to 13, wherein the plurality of dilution chute turbulators have characterizing dimensions between 0.025 inch (0.64 mm) to 0.075 inch (1.91 mm).

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