Additively manufactured tapered transition portion and aft frame for replacement of existing combustor part

Abstract

To provide an additively manufactured tapered transition portion and an aft frame for replacement of existing combustor parts.SOLUTION: A combustor for a gas turbine (GT) system includes a combustor body including a non-additively manufactured (non-AM) part having corrosion at a first level and a replacement additively manufactured (AM) part (210) coupled to the non-AM part. The replacement AM part (210) has corrosion at a second level less than the first level. The replacement AM part (210) includes: an aft section of a tapered transition portion and an aft frame of the combustor body; and a plurality of shared parallel, sintered metal layers extending into the aft section of the tapered transition portion and the aft frame. The replacement AM part (210) may also include a receiving element in a most forward end thereof configured to receive a most rearward remaining end of the non-AM part.SELECTED DRAWING: Figure 7

Description

Technical Field

[0001] The disclosure relates generally to a turbomachinery combustor, and more specifically to an additively manufactured component including a rear frame for replacing at least a rear portion of a tapered transition section of a combustion liner and existing components of a combustor body.

Background Art

[0002] A gas turbine system includes a combustion section including a plurality of combustors in which fuel is burned to create a flow of combustion gases that is converted into kinetic energy in a downstream turbine section. Current combustors include a number of parts that need to be welded. For example, the combustor body may include a combustion liner having a cylindrical portion and a tapered transition section having a rear frame at the rear end of the tapered transition section. Note that the cylindrical portion and the tapered transition section may be made of pressed metal, and the rear frame may be made by casting. The rear frame couples the tapered transition section to the turbine inlet and is welded to the rear end of the tapered transition section. The weld represents an example of a plurality of life-limiting structures within the combustor body. Current approaches for repairing or replacing the tapered transition section and / or the rear frame typically involve individually replacing each component with the same structure and material, including welds and other potentially life-limiting structures that limit the life.

[0003] Additive manufacturing, such as direct metal laser melting (DMLM) and selective laser melting (SLM), has emerged as a reliable manufacturing method for manufacturing combustor components. It is understood that the size of the build platform and the size of the processing chamber limit the size of the combustor components that can be manufactured using these techniques. Furthermore, large components typically require longer build times, so the use of additive manufacturing for large-scale combustor components may not be readily adopted.

Summary of the Invention

[0004] All aspects, examples, and features shown below can be combined in technically possible ways.

[0005] One aspect of the disclosure is a method of repairing a combustor including a combustor body including a combustion liner including a cylindrical portion and a tapered transition portion, and an aft frame coupled to an aft end of the tapered transition portion, the method comprising removing a non-additively manufactured (non-AM) part of the combustor body and creating a removed non-AM part and a remaining non-AM part of the combustor body, the removed non-AM part including at least a rear portion of the tapered transition portion and the aft frame of the combustor bodywherein the removed non-AM part includes at least an aft section of the tapered transition portion and the aft frame of the combustor body) and a step of additively manufacturing a replacement additively manufactured (AM) part for the removed non-AM part, the replacement AM part including a receiving element configured to receive part of the remaining non-AM part of the combustor body and a plurality of parallel, sintered metal layers; wherein the replacement AM part includes at least the aft section of the tapered transition portion and the aft frame of the combustor body), and a step of coupling the replacement AM part to the remaining non-AM part of the combustor body.,

[0006] Another aspect of the disclosure includes the preceding aspects, wherein the removed non-AM part includes at least one life-limiting structure selected from a group comprising: a weld, a hot spot, and a high stress geometry.

[0007] Another aspect of the disclosure includes any of the preceding aspects, wherein the coupling includes welding the replacement AM part to the remaining non-AM part of the combustor body where the remaining non-AM part meets the receiving element.

[0008] Another aspect of the disclosure includes any of the preceding aspects, wherein the replacement AM part includes at least one cooling passage defined therein.

[0009] Another aspect of the disclosure includes any of the preceding aspects, wherein the plurality of parallel, sintered metal layers in the replacement AM part extends into the aft section of the tapered transition portion and the aft frame.

[0010] Another aspect of the disclosure includes any of the preceding aspects, wherein the removed non-AM part further includes an axial fuel stage (AFS) injector mount upstream of the tapered transition portion, the replacement AM part further includes the AFS injector mount, and the plurality of parallel, sintered metal layers in the replacement AM part extends into the AFS injector mount.

[0011] Another aspect of the disclosure includes any of the preceding aspects, wherein the removed non-AM part further includes a part of the cylindrical portion of the combustion liner upstream of the AFS injector mount, the replacement AM part further includes the part of the cylindrical portion of the combustion liner, and the plurality of parallel, sintered metal layers in the replacement AM part extends into the part of the cylindrical portion of the combustion liner.

[0012] Another aspect of the disclosure includes any of the preceding aspects, and the removed non-AM part includes a first material, and the replacement AM part includes a second material different than the first material.

[0013] Another aspect of the disclosure includes a combustor for a gas turbine (GT) system, the combustor including a combustor body including a combustion liner including a cylindrical portion and a tapered transition portion, an axial fuel stage (AFS) injector mount, and an aft frame at an aft end of the tapered transition portion, the combustor body including a first, non-additively manufactured (non-AM) part having corrosion at a first level and a second additively manufactured (AM) part coupled to the first non-AM part, the second AM part having corrosion at a second level less than the first level, the second AM part including at least an aft section of the tapered transition portion and the aft frame, and a plurality of shared parallel sintered metal layers extending to the at least aft section of the tapered transition portion and the aft frameand a plurality of shared parallel, sintered metal layers extending into the at least aft section of the tapered transition portion and the aft frame). ,

[0014] Another aspect of the disclosure includes any of the preceding aspects, wherein the second AM part includes a receiving element configured to receive part of the first non-AM part and join the first non-AM part and the second AM part.

[0015] Another aspect of the disclosure includes any of the preceding aspects, further including a weld coupling the first non-AM part and the second AM part.

[0016] Another embodiment of the disclosure includes any of the preceding embodiments, wherein the first non-AM part includes a first material, and the second AM part includes a second material different than the first material.

[0017] Another aspect of the disclosure includes any of the preceding aspects, wherein the second AM part includes at least one cooling passage defined therein that was not present in the first non-AM part.

[0018] Another aspect of the disclosure includes any of the preceding aspects, wherein the second AM part further includes the AFS injector mount, and the plurality of parallel, sintered metal layers in the second AM part extends into the AFS injector mount.

[0019] Another aspect of the disclosure includes any of the preceding aspects, wherein the second AM part further includes a part of the cylindrical portion of the combustion liner, and the plurality of parallel, sintered metal layers in the second AM part extends into the part of the cylindrical portion of the combustion liner.

[0020] Another aspect of the disclosure includes a component for replacing a first non-additively manufactured (non-AM) part of a combustor body for a gas turbine (GT) system, the first non-AM part including at least an aft section of a tapered transition portion and an aft frame of the combustor body, the component including a second additively manufactured (AM) part including at least the aft section of the tapered transition portion and the aft frame, and a receiving element in a forwardmost end of the second AM part configured to receive a rearwardmost remaining end of the combustor body after removal of the first non-AM part and join the rearwardmost remaining end of the combustor body and the forwardmost end of the second AM part.

[0021] Another aspect of the disclosure includes any of the preceding aspects and further includes a weld coupling a remaining portion of the combustor body and the second AM part.

[0022] Another aspect of the disclosure includes any of the preceding aspects, where the first non-AM part includes a first material and the second AM part includes a second material different than the first material.

[0023] Another aspect of the disclosure includes any of the preceding aspects, where the replacement AM part further includes an axial fuel stage (AFS) injector mount of the combustor body upstream of the tapered transition portion, and the plurality of parallel, sintered metal layers in the replacement AM part extends into the AFS injector mount.

[0024] Another aspect of the disclosure includes any of the preceding aspects, wherein the second AM part further includes a part of a cylindrical portion of a combustion liner of the combustor body upstream of the AFS injector mount, and the plurality of parallel, sintered metal layers in the replacement AM part extends into the part of the cylindrical portion of the combustion liner.

[0025] Two or more aspects described in this disclosure, including those described in the summary section, may be combined to form implementations not specifically described herein. That is, all embodiments described herein can be combined with each other.

[0026] Details of one or more implementations are set forth in the accompanying drawings and the description below. Other features, objects, and advantages will be apparent from the description and drawings, and from the claims.

Brief Description of the Drawings

[0027] These and other features of the disclosure will be more readily understood from the following detailed description of various aspects of the disclosure taken in conjunction with the accompanying drawings that depict various embodiments of the disclosure.

Figure 1

Figure 2

Figure 3

Figure 4

Figure 5A

Figure 5B

Figure 6A

Figure 6B

Figure 7

[0028] Note that the drawings of the disclosure are not necessarily to scale. The drawings are intended to show only typical sides of the disclosure and should not be considered as limiting the scope of the disclosure. In the drawings, like numeration represents similar elements between the drawings.

DETAILED DESCRIPTION OF THE INVENTION

[0029] First, in order to clearly describe the current technology, when referring to and describing relevant mechanical components in an application that serves as an example of a turbomachine, it is necessary to select specific terms. When doing this, if possible, general industry terms should be used and employed in a way that is consistent with their accepted meanings. Unless otherwise stated, such terms should be given a broad interpretation that is consistent with the context of this application and the scope of the appended claims. One of ordinary skill in the art will understand that a particular component may often be referred to using several different or overlapping terms. What may be described in this specification as a single component may include multiple components and may be referred to in another context. Alternatively, what may be described in this specification as including multiple components may be referred to as a single component elsewhere.

[0030] Furthermore, some explanatory terms may be used regularly in this specification, and it should prove useful to define these terms at the beginning of this section. The conventions and their definitions are as follows, unless otherwise specified. As used in this specification, "downstream" and "upstream" are terms indicating directions with respect to the flow of a fluid, such as the flow of a working fluid through a combustor of a turbomachine, or the flow of air through a combustor or coolant through one of the component systems of a turbomachine, for example. The term "downstream" corresponds to the direction of the fluid flow, and the term "upstream" refers to the direction opposite to the flow. The terms "forward" and "rearward" are used without further specificity to indicate direction, with "forward" referring to the front end or compressor end of the turbomachine and "rearward" referring to the rear or turbine end of the turbomachine.

[0031] The term "axial direction" refers to a movement or position parallel to an axis, such as the axis of a combustor or a turbomachine. The term "radial direction" refers to a movement or position perpendicular to an axis, such as the axis of a combustor or a turbomachine. In such cases, when a first component is closer to the axis than a second component, this specification describes that the first component is "radially inside" or "inside" the second component. On the other hand, when a first component is present further away from the axis than a second component, this specification may describe that the first component is "radially outside" or "outside" the second component. Finally, the term "circumferential direction" refers to a movement or position around the axis, for example, the circumferential inner surface of a combustion liner or the circumferential interior of a casing extending around a combustor. As described above, and depending on the context, it is understood that such terms may be applied in relation to the axis of a combustor or the axis of a turbomachine.

[0032] Furthermore, as described below, some explanatory terms may be regularly used in this specification. The terms "first", "second", and "third" may be used in the same sense to distinguish one component from another and are not intended to indicate the position or importance of individual components.

[0033] The terms used in this specification are for the purpose of describing particular embodiments and are not intended to limit the disclosure. As used herein, the singular forms "a", "an", and "the" are intended to include the plural forms as well, unless the context clearly dictates otherwise. Further, when used in this specification, the terms "comprises" and / or "comprising" specify the presence of the described features, integers, steps, operations, elements, and / or components, but do not preclude the presence or addition of one or more other features, integers, steps, operations, elements, components, and / or groups thereof. "Optionally" or "optional" means that the event or feature described thereafter may or may not occur, or that the function described thereafter may or may not be present, and the description includes instances where the event occurs, instances where the function is present, instances where the event does not occur, or instances where the function is not present.

[0034] When an element or layer is referred to as being "on", "engaged to", "connected to", "coupled to", or "mounted on" another element or layer, it can be directly on, engaged, connected, coupled, or mounted to the other element or layer, or there may be intervening elements or layers. In contrast, when an element is referred to as being "directly on", "directly engaged to", "directly connected to", "directly coupled to", or "directly mounted", there are no intervening elements or layers. Other words used to describe the relationship between elements should be interpreted in a similar manner (e.g., "between" and "directly between", "adjacent" and "directly adjacent", etc.). As used herein, the term "and / or" includes any and all combinations of one or more of the associated listed items. The verb forms "coupled" and "mounted" may be used interchangeably herein.

[0035] FIG. 1 shows a partial cross-sectional side view of a conventional combustor 38. The combustor 38 includes a combustor body 40 that includes a combustion liner 42 including a cylindrical portion 44 and a tapered transition portion 46. A flow sleeve 48 may surround at least the cylindrical portion 44 of the combustion liner 42. The cylindrical portion 44 and the flow sleeve 48 are typically made from sheet material that has been rolled or punched into a cylindrical or conical shape and welded together, as represented by weld 45 of the cylindrical portion 44. The flow sleeve 48 is attached around the cylindrical portion 44 of the combustion liner 42 and / or around the tapered transition portion 46 of the combustion liner 42 by mechanical couplers or welds. The cylindrical portion 44 of the combustion liner 42 and the flow sleeve 48 are spaced apart and coupled to a head end assembly 70 of the combustor 38 that includes one or more axially extending fuel nozzles 76.

[0036] The tapered transition portion 46 of the combustion liner 42 is typically made by stamping and welding together metal sheet (see weld 47). The tapered transition portion 46 is welded to the cylindrical portion 44, for example, at weld 49. A rear frame 52 couples the tapered transition portion 46 to a turbine inlet 54. The rear frame 52 is typically made by casting or another process. The rear frame 52 is welded at weld 56 to the rear end portion of the tapered transition portion 46. Small components, such as an axial fuel stage (AFS) fuel injector mount 58, are made using other processes. An opening 60 is machined separately in the combustion liner 42 for the AFS injector 62, and then the mount 58 is welded adjacent to each opening 60 of the combustion liner 42 such that the AFS injector 62 can be bolted to the mount 58. A fuel line 64 for the AFS injector 62 is attached outside of the flow sleeve 48.

[0037] The combustion liner 42, also known as the high temperature gas path (HGP) duct or unitary liner, extends downstream from the head end fuel nozzle assembly 70 (hereinafter "head end assembly 70") and a cap assembly 72 coupled to the rear end of the head end assembly 70 and / or the forward end 74 of the combustor body 40. The head end assembly 70 generally includes at least one axially extending fuel nozzle 76 extending downstream from an end cover 78 and a cap assembly 72 extending radially and axially within the combustion liner 42 downstream of the end cover 78, defining the upstream boundary of the combustion chamber. The head end assembly 70 may include any axially extending fuel nozzle 76 known or hereafter developed for supplying fuel 80 from the axially extending fuel nozzle 76 to the primary combustion zone 82. The axially extending fuel nozzle 76 of the head end assembly 70 supplies a combustible mixture of fuel 80 and compressed air 84 to the primary combustion zone 82. The AFS injector 62 extends radially through the combustion liner 42 downstream of the axially extending fuel nozzle 76. As further described herein, compressed air 84 may be routed to the AFS injector 62 to combine with fuel 80 for combustion in a secondary combustion zone 86 downstream of the primary combustion zone 82.

[0038] As shown, each component of the combustor 38 being described may include a number of sub-parts including mounting fasteners or welds, heat or protective shields, seals, spacers, and couplers. The parts of the combustor body 40 may include any combustion-resistant and oxidation-resistant materials currently known or later developed. Materials include, but are not limited to, an austenite nickel-chromium based alloy such as Inconel 625 or 718, a nickel-chromium-cobalt-molybdenum alloy (NiCrCoMo) (e.g., HA282 or HA233 from Haynes International, Inc.), a nickel-chromium-iron-molybdenum alloy (NiCrFeMo) (e.g., Hastelloy X from Haynes International, Inc.), or a nickel-chromium-cobalt-titanium (NiCrCoTi) alloy (e.g., GTD 262 developed by General Electric Company).

[0039] As shown in FIG. 1, during operation of a conventional combustor 38, components are exposed to a variety of extreme environmental conditions such as high-temperature combustion, vibration, and chemical corrosion, such as oxidation. As also shown in FIG. 1, the combustor 38 exhibits several potential life-limiting structures or features (refer to the areas circled by the circles along the welds 45, 47, 49, 56) that can shorten the life of the combustor 38. For example, the weld 56 between the tapered transition portion 46 and the rear frame 52 may exhibit a life-limiting structure of the combustor 38 due to the high stress experienced at that location. Similarly, the welds 45, 47, 49 may also present structures that reduce the average life of the combustor 38. Other life-limiting structures may include other high-stress geometric structures, hot spots, or other features that can debit the life of the combustor 38.

[0040] To address these issues, embodiments of the disclosure provide a combustor for a GT system that includes a combustor body having (a first) non-additive manufacturing (non-AM) existing component having corrosion at a first level, i.e., due to the use of the combustor, and a (second) replacement additive manufacturing (AM) component coupled to the first non-AM component. The corrosion at the second level of the second replacement AM component is less than that at the first level. The second replacement AM component replaces the removed non-AM component and, in some embodiments, includes at least a rear portion of the tapered transition portion of the combustion liner and the rear frame of the combustor body. By additive manufacturing, the replacement AM component includes a plurality of shared parallel, sintered metal layers extending within the replacement section (e.g., the rear section of the tapered transition portion and the rear frame).

[0041] The replacement AM part may also include a receiving element in a forwardmost end thereof configured to receive a rearwardmost remaining end of the non-AM existing part. The replacement AM part may optionally include additional parts of the combustor, such as an AFS injector mount or a portion of the cylindrical part of the combustion liner. In other embodiments, the replacement AM part may include an AFS injector mount, a portion of the cylindrical part of the combustion liner upstream from the AFS injector mount, and a portion of the tapered transition downstream from the AFS injector mount (possibly including the rear frame). In embodiments where the replacement AM part does not fully protrude to the rear frame, a receiving element for receiving the remaining rearward portion of the tapered transition may be provided at the rearmost end of the replacement AM part.

[0042] The replacement AM part enables the replacement / repair of existing parts having structures that limit life, such as welds, high-stress shapes, hot spots, or other factors that may shorten the life of the combustor. The replacement AM part can extend the life of the combustor without using a life-limiting structure such as a weld, or by moving the life-limiting structure to another, better location. The replacement AM part can also be made of a better material than the removed non-AM part to extend the life of the combustor. The replacement AM part also has a lower manufacturing cost compared to manufacturing the removed non-AM part, as described herein.

[0043] Figure 2 shows a functional block diagram of an exemplary gas turbine (GT) system 90 that can incorporate various embodiments of the combustor 100 of the present disclosure. As shown, the GT system 90 generally includes an inlet section 102 that can include a series of filters, cooling coils, moisture separators, and / or other devices for purifying and otherwise conditioning the working fluid (e.g., air) 104 entering the GT system 90. The working fluid 104 flows into a compressor 106 within a compressor section 107, gradually imparting kinetic energy to the compressor 104 to produce compressed air 108 (hereinafter, "air 108" or "compressed air 108") in a highly energized state. The compressed air 108 is mixed with fuel 120 from a fuel source 122 to form a combustible mixture within at least one combustor 100 within a combustion section 110 operably coupled to the compressor section 107. The combustible mixture is burned to produce high-temperature and high-pressure combustion gases 126.

[0044] The combustion gases 126 flow through a turbine 128 (e.g., an expansion turbine) of a turbine section 129 and are operably coupled to the combustion section 110 to produce work. For example, the turbine 128 may be connected to a shaft 130 such that rotation of the turbine 128 drives the compressor 106 to produce compressed air 108. Alternatively, or additionally, the shaft 130 may connect the turbine 128 to a generator 132 to generate electricity. The exhaust gases 134 from the turbine 128 flow through an exhaust section 136 that connects the turbine 128 to an exhaust stack 138 downstream of the turbine 128. The exhaust section 136 may include, for example, a heat recovery steam generator (not shown) for scrubbing and extracting additional heat from the exhaust gases 134 before they are released to the environment. When multiple combustors 100 are used, they may be circumferentially spaced around the turbine inlet 140 of the turbine 128.

[0045] In one embodiment, the GT system 90 may include a commercially available engine model from GE Vernova in Cambridge, Massachusetts. The present disclosure is not limited to any particular GT system and may be embedded in relation to engines including, for example, GE Vernova's HA, F, B, LM, GT, TM, and E-class engine models, as well as engine models from other companies. Further, the present disclosure is not limited to any particular turbomachine and may be applicable to, for example, steam turbines, jet engines, compressors, turbofans, and the like.

[0046] FIG. 3 shows a cross-sectional perspective view and an exploded view of a combustor 100 including a component (replacement AM component 210) according to an embodiment of the disclosure.

[0047] Referring to FIGS. 3-4, an embodiment of the disclosure may include a method of repairing a combustor 38 (FIG. 1). As shown in FIG. 3, a combustor 100 to be repaired includes much of the structure of the combustor 38 (FIG. 1). Briefly described, the combustor 100 includes a combustor body 160 including a combustion liner 162 including a cylindrical portion 164 and a tapered transition portion 166, and a rear frame 168 coupled to a rear end (right end as shown) of the tapered transition portion 166. A flow sleeve 169 may surround the cylindrical portion 164 of the combustion liner 162. The combustor 100 may also include an axial fuel stage (AFS) injector mount 170 for mounting an AFS injector 172 (FIG. 3). The combustor 100 may also include a head end fuel nozzle assembly 174 (hereinafter “head end assembly 174”) and a cap assembly 176 coupled to a front end 177 of the combustor body 160. The head end assembly 174 generally includes at least one axially extending fuel nozzle 178 for supplying fuel 180 and compressed air 182 to a primary combustion zone 184. The AFS injector 172 extends radially through the combustion liner 162 downstream of the axially extending fuel nozzle 178. A fuel line 179 for the AFS injector 172 may be attached outside the flow sleeve 169 or may be formed inside thereof. The compressed air 182 may be routed to the AFS injector 172 for combination with the fuel 180 for combustion in a secondary combustion zone 186 downstream of the primary combustion zone 184.

[0048] As shown in FIG. 4, this method may include removing non-AM existing part 200 of combustor body 160 after use of the combustor. The removal process may include any process known currently or developed later that is sufficient to remove the desired part, such as cutting, machining, grinding, etc. This removal process creates the removed non-AM part 200 of combustor body 160 and the remaining non-AM part 202. The removed non-AM part 200 can take various forms. In one embodiment, as shown in FIG. 4, the removed non-AM part 200 includes at least a portion of the tapered transition section 166 of combustor body 160 and the rear portion of rear frame 168. That is, a part of the rear portion of tapered transition section 166, i.e., the front or upstream portion in front of its downstream rear end, is removed, and the entire rear frame 168 is removed.

[0049] The range of the rear portion of tapered transition section 166 to be removed can be defined based on several factors. For example, the cutting position can be selected to provide the interface required for the new part. In particular, the cutting position can be performed to remove as many life-limiting structures as possible from combustor body 160. Thus, the removed non-AM part 200 may include at least one life-limiting structure, such as, but not limited to, weld 56, known hot spots, and high-stress shapes. FIGS. 3 - 4 show a tapered transition section 166 including an internal chamber 190 and an integral flow sleeve or impingement flow sleeve 192 (with holes therein, not shown), but it is recognized that the flow sleeve is optional regardless of the embodiment.

[0050] This removal process can be performed after the use of the combustor 100. During the use of the combustor 100, prior to the removal process, the components of the combustor 100 are subject to corrosion commensurate with their use. For example, the combustion liner 162 can have oxidation, cracks, burn through, distortion, and / or creep thereon or therein. In any case, the removed non-AM part 200 has corrosion thereon at a first level, e.g., corrosion commensurate with its material, the environment to which the combustor 100 is exposed, and the period of use of the combustor 100. Thus, the level and type of corrosion can vary, among other things, depending on the removed non-AM part 200. Although the first level of corrosion can vary, in one example, it can represent a level of use (including any of the aforementioned problems) beyond which the part is no longer new and corrosion prevents the part from completing the next combustion maintenance interval.

[0051] FIG. 4 also schematically shows the state of additive manufacturing of an exchangeable additive manufacturing (AM) part 210 that replaces the removed non-AM part 200. The additive manufacturing process will be described later in this specification. In the exemplary figure, the exchangeable AM part 210 includes at least the rear portion of the tapered transition portion 166 and the rear frame 168 of the combustor body 160. That is, the exchangeable AM part 210 includes at least the same parts as the removed non-AM part 200. However, the exchangeable AM part 210 does not include at least one life-limiting structure found in the removed non-AM part 200. In the example of FIG. 4, since the exchangeable AM part 210 is additively manufactured with the rear portion of the tapered transition portion 166 and the rear portion of the rear frame 168 as an integral body, it does not include the weld 56. Further, since the exchangeable AM part 210 is not required by the additive manufacturing of the rear portion of the tapered transition portion 166, it does not include a part of the weld 47 that normally joins the longitudinal ends of the punched portion of the tapered transition portion 166 (see the remaining non-AM part 202 in FIG. 4). As a result of the additive manufacturing, there is no mechanical connection between the various parts (i.e., all are integrated).

[0052] Additive manufacturing also enables the replacement AM part 210 to be made of a material different from the removed non-AM part 200 (FIG. 4). That is, the removed non-AM part 200 (FIG. 4) may include a first material, and the replacement AM part 210 may include a second material different from the first material. As described herein, the removed non-AM part 200 may be made of, but is not limited to, HA282 or HA233, Inconel 625 or 718, Hastelloy X, or GTD262. In contrast, the replacement AM part 210 may be made of an austenitic nickel-chromium-based alloy such as a cobalt-chromium-molybdenum (CoCrMo) alloy, stainless steel, nickel-chromium-molybdenum-niobium alloy (NiCrMoNb) (e.g., Inconel 625 or Inconel 718), any non-reactive metal such as a nickel-chromium-iron-molybdenum alloy (NiCrFeMo) (e.g., Hastelloy® X available from Haynes International, Inc.), or a nickel-chromium-cobalt-molybdenum alloy (NiCrCoMo) (e.g., Haynes 282 available from Haynes International, Inc.). Other possibilities include, for example, Rene 52, CM 247, Mar M 247, and any precipitation hardenable (PH) nickel alloys. The only limitation on the different metals is that they need to be able to be joined, for example through welding, to make the operating combustor 100.

[0053] The replacement AM component 210 may also include a plurality of additional structures not seen in the removed non-AM component 200. By additive manufacturing, the replacement AM component 210 includes a tapered transition portion 166 and a plurality of parallel sintered metal layers 216 extending at least into the (new) rear section of the (new) rear frame 168. The replacement AM component 210 may include a receiving element 212 configured at a receiving end 214 of the remaining non-AM components 202 of the combustor body 160. In the example shown in FIGS. 3-4, the receiving element 212 includes a radially outward extending recess that configures the receiving end 214 of the remaining non-AM components 202 in the form of its cut end, i.e., a male-female fit. It is recognized that the receiving element 212 can include a variety of alternative structures for the receiving end 214 of the remaining non-AM components 202, including, but not limited to, a forked element, a radially inward extending indent, or a simple butt joint interface.

[0054] The replacement AM component 210 may also include any kind of additional cooling passages therein. That is, the replacement AM component 210 may include at least one cooling passage defined therein, which is not seen in the removed non-AM component 200. In one non-limiting example shown in FIGS. 3-4, the rear frame 168 includes a new cooling passage 217 therein. In another example, if there is no flow sleeve or impingement flow sleeve 192 around the inner chamber 190 of the tapered transition portion 166 in the removed non-AM component 200, a tapered transition portion 166 may be added in the replacement AM component 210. In another example, if a flow sleeve or impingement flow sleeve 192 is present in the removed non-AM component 200, the number, size, and / or position of the impingement openings 194 may be changed to direct cooling air (e.g., compressed air 118) to different regions of the tapered transition portion 166. The replacement AM component 210 may also include any other kind of advantageous structure that is seen in current newly manufactured combustors but was not present in previously manufactured combustors.

[0055] Figure 3 shows replacement AM part 210 coupled to remaining non-AM parts 202 of combustor body 160. The coupling may include welding replacement AM part 210 to remaining non-AM part 202 of combustor body 160 where rearwardmost remaining end 214 of remaining non-AM part 202 meets receiving element 212. The welding may include permanently fixing and / or sealing the parts together using any welding process known currently or developed later, e.g., TIG welding, MIG welding, etc., based on the different materials of the parts. When complete, as shown in Figure 3, combustor body 160 includes one or more welds 218, shown by dashed reference, that couple the tapered transition 166 and the rear portion of rear frame 168 to remaining non-AM part 202 of combustor body 160. In contrast to weld 56, as shown in Figure 1, in the sharp and high stress shape between the rear portion of tapered transition 46 and rear frame 52, as shown in Figure 3, weld 218 is upstream in a linear position within tapered transition 166. This position reduces and in some cases eliminates properties that shorten the life of the weld.

[0056] Figures 5A and 6A show cross-sectional views of combustor 100 according to alternative embodiments, and Figures 5B and 6B show cross-sectional views of replacement AM part 210 for combustor 100 of Figures 5A and 6A, respectively. In these alternative embodiments, the removed non-AM part 200 and replacement AM part 210 may include more of the rear portion of combustor body 160. That is, the cut line of the removed non-AM part 200 is at the left end of the drawing (i.e., near head end assembly 174). For example, as shown in the cross-sectional views of Figures 5A-B, replacement AM part 210 further includes AFS injector mount 170, and the plurality of parallel sintered metal layers 216 of replacement AM part 210 also extend into AFS injector mount 170. Similarly, the removed non-AM part 200 (not shown) may further include AFS injector mount 170 upstream of tapered transition section 166. In the example of Figures 5A-B, replacement AM part 210 does not include weld 56 between tapered transition section 166 and rear frame 168 as shown in Figures 1 and 4 (i.e., non-AM part 200), so that by additive manufacturing of the rear portions of tapered transition section 166 and rear frame 168, weld 56 is not required. Also, replacement AM part 210 of Figures 5A-B does not require additive manufacturing of the rear portion of tapered transition section 166, so it does not include any of welds 47 (see Figures 1 and 4) that normally join to the longitudinal ends of the pressed portion of tapered transition section 166. Also, weld 49 that normally joins conical transition piece 166 and cylindrical portion 164 may be replaced with weld 218 similar to weld 218 described with respect to Figure 3.

[0057] In another example, as shown in FIGS. 6A - B, the replacement AM part 210 further includes a portion of the cylindrical portion 164 of the combustion liner 162 (the left side of the AFS injector mount 170 as shown), and a plurality of parallel sintered metal layers 216 within the replacement AM part 210 extend into a portion of the cylindrical portion 164 of the combustion liner 162. Similarly, the removed non - AM part (not shown) further includes a portion of the cylindrical portion 164 of the combustion liner 162 upstream of the AFS injector mount 170. The replacement AM part 210 of FIGS. 6A - B does not include any of the welds 47 (see FIGS. 1 and 4) that normally join the longitudinal ends of the pressed portion of the tapered transition 166, as this is not required for the additive manufacturing of the rear portion of the tapered transition 166. Also, the weld 49 that normally joins the cylindrical portion 164 and the tapered transition piece 166 may be replaced with a weld 218. Further, the cylindrical portion of the replacement AM part 210 of FIGS. 6A - B does not include the corresponding portion of the weld 45 (see FIG. 1) that normally joins the longitudinal ends of the punched portion of the cylindrical portion 164, because the additive manufacturing of the portion of the cylindrical portion 164 renders the downstream portion of the weld 45 unnecessary.

[0058] While a particular arrangement of the replacement AM part 210 is illustrated and described herein, it is emphasized that the replacement AM part 210 may include any additional structure of the combustor 100 that is capable of being additively manufactured. For example, the replacement AM part 210 can include, among other structures, any kind of flow sleeve, such as 169, cooling passages, AFS injector openings of the combustor liner 162, fuel lines, and / or impingement flow sleeves.

[0059] Embodiments of the present disclosure may also include parts for replacing the removed non-AM parts 200 of the combustor body 160 for the GT system 90, i.e., the replacement AM parts 210 described previously. As described above, the removed non-AM parts 200 may include the rear portion of the combustor body 160 and the rear portion of the rear frame 168. This component includes the replacement AM parts 210, which may at least include the tapered transition portion 166 and the rear portion of the rear frame 168. Further, this component may include a receiving element 212 at the foremost end of the replacement AM parts 210 configured to receive the remaining end portion 214 of the very end of the combustor body 160 after the removal of the removed non-AM parts 200, and is configured to join the remaining end portion 214 of the very end of the combustor body 160 and the rearmost end of the replacement AM parts 210. This component may include a welded portion 218 of the remaining end portion 214 of the very end of the combustor body 160 and the replacement AM parts 210. As described above, the removed non-AM parts 200 may include a first material, and the replacement AM parts 210 may include a second material different from the first material.

[0060] In other embodiments shown in FIGS. 5A - B, the AM part 210 for component replacement may further include an AFS injector mount 170 upstream of the tapered transition portion 166, and a plurality of parallel sintered metal layers 216 of the AM part 210 for replacement may extend to the AFS injector mount 170. In other embodiments, as shown in FIGS. 6A - B, the AM part 210 for component replacement may further include a part of the cylindrical portion 164 of the combustion liner 162 upstream of the AFS injector mount 170, and a plurality of parallel sintered metal layers 216 of the AM part 210 for replacement may extend to a part of the cylindrical portion 164. In other embodiments (not shown), the AM part 210 for replacement may include an AFS injector mount(s) 170, a part of the cylindrical portion 164 of the combustion liner 162 upstream of the AFS injector mount(s), and a part of the tapered transition portion 166 (possibly including the rear frame 168) downstream of the AFS injector mount(s). In embodiments where the AM part 210 for replacement does not extend completely to the rear frame 168, a receiving element 212 may be provided at the rear end of the AM part 210 for replacement to receive the foremost end of the remaining rear part of the tapered transition portion 166.

[0061] The disclosed embodiments also include a combustor 100 for a GT system 90. As shown in FIGS. 3, 5A, and 6A, the combustor 100 includes a combustor body 160 that includes a combustion liner 162 that includes a cylindrical portion 164 and a tapered transition portion 166, an AFS injector mount 170, and a rear frame 168 at the rear end of the tapered transition portion 166. The combustor body 160 includes remaining non-AM parts 202 having corrosion at a first level, i.e., due to the use of the combustor 100, and second replacement AM parts 210 coupled to the remaining non-AM parts 202. The replacement AM parts 210 are formed after the use of the combustor 100 and, for replacing a part thereof, the replacement AM parts 210 have less corrosion at a second level than at the first level. As described herein, in various embodiments, the replacement AM parts 210 include at least a rear portion of the tapered transition portion 166 and the rear frame 168. Also, by additive manufacturing, the replacement AM parts 210 include a plurality of shared parallel sintered metal layers 216 that extend to at least a rear portion of the tapered transition portion 166 and the rear frame 168. In other embodiments shown in FIGS. 5A-B, the replacement AM parts 210 may further include the AFS injector mount(s) 170, and the plurality of parallel sintered metal layers 216 within the replacement AM parts 210 may extend into the AFS injector mount(s) 170. In other embodiments, as shown in FIGS. 6A-B, the replacement AM parts 210 may further include a portion of the cylindrical portion 164 of the combustion liner 162, and the plurality of parallel sintered metal layers 216 within the replacement AM parts 210 may extend into a portion of the cylindrical portion 164.

[0062] As described above in this specification, the AM replacement part 210 of the combustor 100 may also include a receiving end portion 214 of the remaining non-AM parts 202 and a receiving element 212 configured to couple the remaining non-AM parts 202 and the AM replacement part 210. As described above, weld the remaining joint 218 between the non-AM part 202 and the AM replacement part 210. Further, as described in this specification, the remaining non-AM parts 202 may include a first material, and the AM replacement part 210 may include a second material different from the first material. As shown in FIG. 4, the AM replacement part 210 may include at least one cooling passage 217 defined therein, which does not exist in the removed non-AM part 200.

[0063] As shown in FIGS. 3, 5A, and 6A, the combustor 100 generally terminates at a point adjacent to the first stage 230 of the stationary nozzle 232 of the turbine 128. The first stage 230 of the stationary nozzle 232 at least partially defines the turbine 128 from the turbine inlet 140. The combustion liner 162 at least partially defines a hot gas path (HGP) for routing the combustion gas 126 from the primary combustion zone 184 and the secondary combustion zone 186 to the turbine inlet 140 of the turbine 128 during operation of the GT system 90.

[0064] During operation, as shown in FIGS. 3, 5A, and 6A, compressed air 182 flows from compressor 106 and passes through various fluid flow path(s). A portion of the compressed air 182 is routed, for example, through flow sleeve 169 to head end assembly 174 of combustor 100, where it reverses direction and is directed through axially extending fuel nozzle 178. The compressed air 182 is mixed with fuel 180 to form a first combustible mixture, which is thereby injected into primary combustion zone 184. The first combustible mixture is burned to produce combustion gas 126. A second portion of the compressed air 182 passes through radially extending AFS injector 172 and can be mixed with fuel 180 from fuel passage 179 (e.g., a conduit from fuel source 122 provided as an outer tube (shown) or flow sleeve 169) to form a second combustible mixture. The second combustible mixture is injected into the high temperature gas path (HGP) through liner 162. The second combustible mixture is at least partially mixed with combustion gas 126 and burned in secondary combustion zone 186. Combustion liner 162 at least partially defines a high temperature gas path (HGP) for routing combustion gas 126 from primary combustion zone 184 and secondary combustion zone 186 to turbine inlet 140 of turbine 128 during operation of GT system 90.

[0065] The replacement AM part 210 may be additively manufactured using any currently known or later developed technology capable of forming a large, one-piece body. As shown in FIGS. 4, 5B, and 6B, the replacement AM part 210 includes a plurality of parallel sintered metal layers 216 of a selected metal. FIG. 7 shows a schematic / block diagram of an exemplary computerized metal powder additive manufacturing system 310 (hereinafter “AM system 310”) for generating the replacement AM part 210, with only one layer shown. Although the teachings of the disclosure are described in connection with constructing the replacement AM part 210 using multiple melt beam sources 312, 314, 316, 318, it is emphasized and will be readily recognized that the teachings of the disclosure are equally applicable to constructing the replacement AM part 210 using any number of melt beam sources.

[0066] In this example, the AM system 310 is arranged for direct metal laser melting (DMLM). It is understood that the general teachings of the present disclosure are equally applicable to other forms of metal powder additive manufacturing such as selective laser melting (SLM), and possibly other forms of additive manufacturing (i.e., other than metal powder applications). The layers of the replaceable AM part 210 on the build platform 320 are shown in FIG. 7 as rectangular arc polygons (such as the cross-section of the tapered transition portion 166). However, it is understood that the additive manufacturing process can be easily adapted to manufacture parts of any shape of the replaceable AM part 210 on the build platform 320. Further, in the exemplary embodiments described herein, the cross-sectional shape can transition from a rectangular arc polygon to a circular shape (e.g., the cylindrical portion 164 of the combustor body 104).

[0067] The AM system 310 generally includes an additive manufacturing control system 330 (the "control system") and an AM printer 332. As will be described later, the control system 330 uses a plurality of melting beam sources 312, 314, 316, 318 to execute a set of computer-executable instructions or code 334 to generate the replaceable AM part 210. In the example shown, the four melting beam sources may include four lasers. However, the teachings of the disclosure are applicable to any melting beam source, such as an electron beam, a laser, etc. The control system 330 is shown implemented on a computer 336 as computer program code. In this context, the computer 336 includes a memory 338 and / or a storage system 340, a processor unit (PU) 344, an input / output (I / O) interface 346, and a bus 348. Further, the computer 336 is shown in communication with external I / O devices / resources 350.

[0068] Generally, the processor unit (PU) 344 executes computer program code 334 stored in the memory 338 and / or the storage system 340. While executing the computer program code 334, the processor unit (PU) 344 can read and write data between the memory 338, the storage system 340, the I / O device 350, and / or the AM printer 332. The bus 348 provides a communication link between each component of the computer 336, and the I / O device 350 can include any device that enables a user to interact with the computer 336 (e.g., a keyboard, a pointing device, a display, etc.).

[0069] The computer 336 merely represents various possible combinations of hardware and software. For example, the processor unit (PU) 344 may include a single processing unit or may be distributed across one or more locations, e.g., one or more processing units on a client and a server. Similarly, the memory 338 and / or the storage system 340 may exist in one or more physical locations. The memory 338 and / or the storage system 340 can include any combination of various types of non-transitory computer-readable storage media, including magnetic media, optical media, random access memory (RAM), read-only memory (ROM), etc. The computer 336 can include any type of computing device, such as an industrial controller, a network server, a desktop computer, a laptop, a handheld device, etc.

[0070] As described above, the AM system 310, and particularly the control system 330, executes code 334 to generate replacement AM parts 210. The code 334 can include, among other things, a set of computer-executable instructions 334S (also referred to herein as "code 334S") for operating the AM printer 332 as a system, and a set of computer-executable instructions 334O (also referred to herein as "code 334O") for defining each object such as the replacement AM part 210 physically generated by the AM printer 332. As described herein, the additive manufacturing process begins with a non-transitory computer-readable storage medium (e.g., memory 338, storage system 340, etc.) that stores the code 334. The set of computer-executable instructions 334S for operating the AM printer 332 can include any software code currently known or later developed that can operate the AM printer 332.

[0071] The set of computer-executable instructions 334O that define the AM part 210 for exchange may include an accurately defined 3D model of the AM part 210 for exchange and can be generated from any system of well-known computer-aided design (CAD) software systems such as AutoCAD®, TurboCAD®, DesignCAD 3D Max, etc. In this regard, the code 334O can include currently known file formats or file formats developed in the future. Further, the representative code 334O of the AM part 210 for exchange may be translated between different formats. For example, the code 334O may include a standard tessellation language (STL) file created for a stereolithography CAD program of 3D Systems or an American Society of Mechanical Engineers (ASME) standard in an extensible markup language (XML)-based format designed so that any CAD software can describe any three-dimensional shape and configuration, an additive manufacturing file (AMF), which may be included in an object manufactured by any AM printer. The representative code 334O of the AM part 210 for exchange may, if necessary, be converted into a set of data signals and transmitted, or received as a set of data signals, converted into code, stored, etc. The code 334O may be configured to enable the formation of boundaries and internal sections in overlapping field regions as described herein according to embodiments of the present disclosure. In any case, the code 334O can be an input to the AM system 310 and may come from a part designer, an intellectual property (IP) provider, a design company, an operator or owner of the AM system 310, or other sources. In any case, the control system 330 executes the codes 334S and 334O, divides the AM part 210 for exchange into a series of thin slices, and assembles them into successive layers of material using the AM printer 332.

[0072] The AM printer 332 may include a processing chamber 360 that is sealed to provide a controlled atmosphere for printing of the replaceable AM part 210. The build platform 320 is where the replaceable AM part 210 is built or is to be built and is disposed within the processing chamber 360. A number of melt beam sources 312, 314, 316, 318 are configured to melt a layer of metal powder on the build platform 320 to produce the replaceable AM part 210. Although four melt beam sources 312, 314, 316, 318 are illustrated, it is emphasized that the teachings of the disclosure are applicable to systems that use any number of sources, such as 1, 2, 3, or 5 or more. As will be appreciated in the art, each melt beam source 312, 314, 316, 318 may have a field that includes a non-overlapping field region that can exclusively melt the metal powder, and two or more sources may include at least one overlapping field region where the metal powder can be melted. In this regard, each melt beam source 312, 314, 316, 318 may generate a melt beam that fuses particles for each slice, as defined by the code 334O.

[0073] For example, in FIG. 7, it is shown that the melt beam source 312 is creating a layer of the replaceable AM part 210 using the melt beam 362 in one region, while the melt beam source 314 is shown creating a layer of the replaceable AM part 210 using the melt beam 362' in another region. Each melt beam source 312, 314, 316, 318 is calibrated in any currently known or later developed method. That is, each melt beam source 312, 314, 316, 318 correlates the predicted position of its laser beam or electron beam relative to the build platform 320 to its actual position to provide an individual position correction (not shown) to ensure its individual accuracy. In one embodiment, each of the plurality of melt beam sources 312, 314, 316, 318 may create melt beams, such as 362, 362', having the same cross-sectional area dimensions (e.g., shape and size during operation), output, and scan speed.

[0074] Continuing with FIG. 7, the applicator (or re - coater blade) 370 may create a thin layer of raw material 372 that spreads as a blank canvas on which each successive slice of the final replacement AM part 210 is created. Various parts of the AM printer 332 may move to accommodate the addition of each new layer. For example, the build platform 320 may descend and / or the chamber 360 and / or the applicator 370 may rise after each layer. This process may use different raw materials in the form of fine - grained metal powders, the stock of which may be held in a chamber or powder reservoir 368 accessible by the applicator 370.

[0075] The processing chamber 360 is filled with an inert gas such as argon or nitrogen and is controlled to minimize or eliminate oxygen. The control system 330 is configured to control the flow of the gas mixture 374 within the processing chamber 360 from a source of inert gas 376. In this case, the control system 330 may control the pump 380 and / or the flow valve system 382 for the inert gas to control the content of the gas mixture 374. The flow valve system 382 may include one or more computer - controllable valves, flow sensors, temperature sensors, pressure sensors, etc. that can accurately control the flow of a particular gas. The pump 380 may be provided with or without the valve system 382. If the pump 380 is omitted, the inert gas can simply enter a conduit or manifold prior to introduction into the processing chamber 360. The source of inert gas 376 can take the form of any conventional source for the materials contained therein, such as a tank, storage layer, or other source. Any sensors (not shown) necessary to measure the gas mixture 374 may be provided. The gas mixture 374 can be filtered using a filter 386 in a conventional manner.

[0076] In operation, a build platform 320 with metal powder thereon is provided within a processing chamber 360, and a control system 330 controls the flow of a mixed gas 374 within the processing chamber 360 from a source of an inert gas 376. The control system 330 also controls an AM printer 332, and in particular, controls an applicator 370 and melting beam sources 312, 314, 316, 318 to sequentially melt layers of metal powder on the build platform 320 to produce a replacement AM part 210 in accordance with the disclosed embodiments. Although a particular AM system 310 is described herein, it is emphasized that the teachings of the disclosure are not limited to any particular additive manufacturing system or method.

[0077] As described herein, once the replacement AM part 210 is formed, it may be coupled to the remaining non-AM part 202 as shown in FIGS. 3, 5A, and 6A. For example, the replacement AM part 210 may be attached to and welded to the remaining non-AM part 202 (e.g., using features such as a receiving end 212).

[0078] The present disclosure provides various technical and commercial advantages, examples of which are discussed herein. The replacement AM part enables replacement / repair of existing parts having structures that limit life, such as welding, high-stress shapes, hot spots, or other factors that may shorten the life of a combustor. The replacement AM part can be created without using a life-limiting structure such as a weld, or by moving the life-limiting structure to another, better location to extend the life of the combustor. The replacement AM part can be made with an improved cooling function and placed in areas known to be hot spots or that may be local. The replacement AM part can also be manufactured from a material superior to the removed non-AM part to extend the life of the combustor and at a lower manufacturing cost compared to manufacturing the non-AM part.

[0079] The approximating language that may be used throughout this specification and the claims is applicable to modify any quantitative representation that could vary tolerably without resulting in a change in the basic function to which it relates. Accordingly, values modified by terms such as “about,” “substantially,” “approximately,” etc. are not to be limited to the exact values specified. In at least some instances, the approximating language may correspond to the precision of the instrument for measuring the value. Here, and throughout the specification and claims, ranges may be combined and / or interchanged. Such ranges are identified and, unless the context or language indicates otherwise, include all sub-ranges subsumed therein. “Approximately” or “about” applied to a particular value of a range applies to both end values and may indicate + / −10% of the recited value where there is no otherwise indicated dependence on the precision of the instrument for measuring the value.

[0080] All means or step plus function elements corresponding structures, materials, acts, and equivalents in the following claims are intended to include any structures, materials, or acts for performing the functions in combination with other specifically claimed claimed elements. The description of the present disclosure is presented for purposes of illustration and description but is not intended to be exhaustive or limiting of the disclosure in the form disclosed. Many modifications and variations will be apparent to those of ordinary skill in the art without departing from the scope and spirit of the disclosure. Embodiments are selected and described in order to best explain the principles of the disclosure and the practical application thereof, and to enable others of ordinary skill in the art to understand the disclosure for various modifications that may be suitable for the particular use contemplated.

Explanation of Reference Numerals

[0081] 38, 100: Combustor 40, 160: Combustor body 42, 162: Combustion liner 44, 164: Cylindrical part 45, 47, 49, 56: Weld 46, 166: Tapered transition part 48, 169: Flow sleeve 52, 168: Rear frame 54: Turbine inlet 58, 170: Axial fuel stage fuel injector mount / AFS fuel injector mount / Mount 60, 194: Opening 62, 172: Axial fuel stage fuel injector / AFS fuel injector 64, 179: Fuel line 70, 174: Head end fuel nozzle assembly / Head end assembly 72, 176: Cap assembly 74, 177: Front end 76, 178: Fuel nozzle 80, 180: Fuel 82, 184: Primary combustion zone 84, 182: Compressed air 86, 186: Secondary combustion zone 90: Gas turbine system / GT system 102: Inlet section 104: Working fluid / Air 106: Compressor 107: Compressor section 108: Compressed air / Air 110: Combustion section 120: Fuel 122: Fuel supply source 126: Combustion gas 128: Turbine 129: Turbine section 130: Shaft 132: Generator 134: Exhaust gas 136: Exhaust section 138: Exhaust stack 140: Turbine inlet 190: Internal chamber 202: Non-AM parts 210: Replaceable AM parts 212: Receiving end 214: Rear remaining end 216: Multiple parallel sintered metal layers 217: New cooling passage 218: Weld 230: First stage 232: Stationary nozzle 310: Metal powder additive manufacturing system / AM system 312, 314, 316, 318: Melt beam source 320: Build platform 330: Additive manufacturing control system 332: AM printer 334, 334O, 334S: Computer-executable instructions or code / Computer program code 336: Computer 338: Memory 340: Storage system 344: Processor unit (PU) 346: Input / output (I / O) interface 348: Bus 350: I / O device 360: Processing chamber 362, 362‘: Melt beam 368: Accessible chamber / Powder reservoir 370: Applicator / Re-coating blade 372: Raw material 374: Gas mixture 376: Inert gas 380: Pump 382: Flow valve system386: Filter

Claims

1. A method for repairing a combustor (100) including a combustor body (160), wherein the combustor body (160) includes a combustion liner (162) including a cylindrical portion (164) and a tapered transition portion (166), and a rear frame (168) coupled to a rear end of the tapered transition portion (166), the method comprising: removing non-additive manufacturing (non-AM) parts of the combustor body (160); creating a remaining non-AM part (202) of the combustor body (160) and the removed non-AM part (200), wherein the removed non-AM part (200) includes at least a rear portion of the rear frame (168) and the tapered transition portion (166) of the combustor body (160); additively manufacturing a replacement additive manufacturing (AM) part (210) for the removed non-AM part (200), wherein the replacement AM part (210) includes a receiving element (212) configured to receive a part of the remaining non-AM part (202) of the combustor body (160) and a plurality of parallel sintered metal layers (216), and the replacement AM part (210) includes at least the rear frame (168) of the combustor body (160) and the rear portion of the tapered transition portion (166); coupling the replacement AM part (210) to the remaining non-AM part (202) of the combustor body (160).

2. The method of claim 1, wherein the removed non-AM part (200) includes at least one life-limiting structure selected from the group consisting of welds, hot spots, and high stress shapes.

3. The method of claim 1, wherein the coupling step includes welding the replacement AM part (210) to the remaining non-AM part (202) of the combustor body (160) at a location where the remaining non-AM part (202) contacts the receiving element (212).

4. The method of claim 1, wherein the replacement AM part (210) includes at least one cooling passage (217) defined therein that is not present in the removed non-AM part (200).

5. The method of claim 1, wherein the plurality of parallel sintered metal layers (216) in the replacement AM part (210) extend to the rear frame (168) and the rear portion of the tapered transition portion (166).

6. The removed non-AM component (200) further includes an axial fuel stage (AFS) injector mount (170) upstream of the tapered transition section (166), and the replacement AM component (210) further includes the AFS injector mount (170) and a plurality of parallel sintered metal layers (216) extending into the AFS injector mount (170), the method according to claim 5.

7. The removed non-AM component (200) further includes a part of the cylindrical portion (164) of the combustion liner (162) upstream of the AFS injector mount (170), and the replacement AM component (210) further includes a plurality of parallel sintered metal layers (216) extending into a part of the cylindrical portion (164) of the combustion liner (162) and a part of the cylindrical portion (164) of the combustion liner (162), the method according to claim 6.

8. The removed non-AM component (200) includes a first material, and the replacement AM component (210) includes a second material different from the first material, the method according to claim 1.

9. A combustor (100) for a gas turbine (GT) system (90), The combustor (100) includes a combustor body (160), The combustor body (160) includes a combustion liner (162) including a cylindrical portion (164) and a tapered transition section (166), an axial fuel stage (AFS) injector mount (170), a rear frame (168) at the rear end of the tapered transition section (166), and includes The combustor body (160) includes a first non-additive manufacturing (non-AM) component (202) having corrosion at a first level and a second additive manufacturing (AM) component (210) coupled to the first non-AM component (202), The second AM component (210) has corrosion at a second level smaller than the first level, The second AM component (210) includes at least one rear portion of the tapered transition section (166) and the rear frame (168) and a plurality of shared parallel sintered metal layers (216) extending into at least the rear portion of the tapered transition section (166) and the rear frame (168), the combustor (100).

10. The second AM component (210) includes a receiving element (212) configured to receive a part of the first non-AM component (202) and join the first non-AM component (202) and the second AM component (210), the combustor (100) according to claim 9.

11. The combustor (100) according to claim 9, further comprising a welded joint connecting the first non-AM component (202) and the second AM component (210).

12. The combustor (100) according to claim 9, wherein the first non-AM component (202) includes a first material, and the second AM component (210) includes a second material different from the first material.

13. The combustor (100) according to claim 9, wherein the second AM component (210) includes at least one cooling passage (217) defined therein.

14. The combustor (100) according to claim 9, wherein the second AM component (210) further includes an AFS injector mount (170), and a plurality of parallel sintered metal layers (216) of the second AM component (210) extend into the AFS injector mount (170).

15. The combustor (100) according to claim 14, wherein the second AM component (210) further includes a part of the cylindrical portion (164) of the combustion liner (162) and a plurality of parallel sintered metal layers (216) of the second AM component (210) extending to a part of the cylindrical portion (164) of the combustion liner (162).

Images