Axial fuel stage immersed injector and combustor body additively manufactured with different material

Abstract

To provide an axial fuel stage immersed injector and a combustor body additively manufactured with different materials.SOLUTION: A combustor (100) for a gas turbine system (102) includes a combustion liner (160) including a primary combustion zone (162) and a secondary combustion zone (164). The combustor body (158) is additively manufactured and made of a first material. The combustor (100) also includes axial fuel stage (AFS) immersed injectors (180) extending radially into the combustion liner (160) in the secondary combustion zone (164). Each AFS immersed injector (180) extends through an opening (182) in the combustion liner (160) and is additively manufactured with a second material different from the first material. A coupler (190) fixes each AFS immersed injector (180) to the respective opening (182) in the combustion liner (160). The additive manufacturing results in as much as a 70% reduction in parts within a given combustor (100) and allows use of high temperature and high oxidation tolerant, hot gas path (HGP) materials for the AFS immersed injectors (180).SELECTED DRAWING: Figure 3

Description

Technical Field

[0001] The disclosure relates generally to turbomachinery combustors, and more specifically to axial fuel stage immersed injectors and combustor bodies additively manufactured with different materials.

Background Art

[0002] A gas turbine system includes a combustion section including a plurality of combustors where fuel is burned to create a flow of combustion gases that is converted to kinetic energy in a downstream turbine (e.g., an expansion turbine). Current combustors include a number of components that are separately manufactured and need to be assembled together, which can be a complex and time-consuming process. Additive manufacturing such as direct metal laser melting (DMLM) and selective laser melting (SLM) has emerged as a reliable manufacturing method for component manufacturing.

[0003] In certain combustors, axial fuel stage (AFS) immersed injectors extend radially into the combustion liner to burn fuel in a secondary combustion zone downstream of the primary combustion zone. AFS immersed injectors are used to provide a higher energy and more efficient combustor. Current AFS immersed injectors are made of the same material as other common combustor components. Due to the temperature limitations of current materials, the use of AFS immersed injectors is restricted. For example, the use of hydrogen fuel is not recommended with current AFS immersed injectors because of the high combustion temperature and fast reactivity.

Summary of the Invention

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

[0005] One aspect of the disclosure includes a combustor for a gas turbine system, the combustor including a combustor body including a combustion liner including a primary combustion zone and a secondary combustion zone, the combustor body being additively manufactured and made of a first material, the combustor body, and a plurality of axial fuel stage (AFS) immersed injectors extending radially into the combustion liner in the secondary combustion zone, each AFS immersed injector extending through an opening in the combustion liner, each immersed injector being additively manufactured and made of a second material different than the first material, the plurality of AFS immersed injectors, and a coupler fixing each AFS immersed injector in a respective opening in the combustion liner.

[0006] Another aspect of the disclosure includes any of the preceding aspects and further includes a braze joint seal surrounding each AFS immersed injector at a surface of the combustion liner.

[0007] Another aspect of the disclosure includes any of the preceding aspects, wherein the coupler includes: a sleeve radially extending from an outer portion of the combustion liner at each opening in the combustion liner, each sleeve having an inner surface configured to mate with an outer surface of a respective AFS immersed injector; and a pin extending through an opening in the sleeve and an opening in a radially outer end of each AFS immersed injector.

[0008] Another aspect of the disclosure includes any of the preceding aspects, wherein the coupler includes a tack weld between a radially outer end of each AFS immersed injector and an outer portion of the combustion liner.

[0009] Another aspect of the disclosure includes any of the preceding aspects, and the coupler includes a threaded connection between each AFS immersed injector and the respective opening in the combustion liner.

[0010] Another aspect of the disclosure includes any of the preceding aspects, and each AFS immersed injector has a circular cross-sectional shape.

[0011] Another aspect of the disclosure includes any of the preceding aspects, and each AFS immersed injector has an airfoil cross-sectional shape.

[0012] Another aspect of the disclosure includes any of the preceding aspects, and each AFS immersed injector includes a fuel passage, an air passage, and a plurality of fuel-air nozzles spaced along a length thereof for supplying a fuel and air combustible mixture to the secondary combustion zone from the fuel passage and the air passage.

[0013] Another aspect of the disclosure includes any of the preceding aspects, and further includes a head end fuel nozzle assembly coupled to a forward end of the combustor body for supplying a fuel and air combustible mixture to the primary combustion zone.

[0014] Another aspect of the disclosure includes a gas turbine (GT) system. The GT system includes a compressor section, a combustion section operatively coupled to the compressor section, and a turbine section operatively coupled to the combustion section. The combustion section includes at least one combustor. The at least one combustor is a combustor body including a combustion liner including a primary combustion zone and a secondary combustion zone, wherein the combustor body is additively manufactured and made of a first material. The combustion liner in the secondary combustion zone includes a plurality of axial fuel stage (AFS) immersed injectors extending radially therein. Each AFS immersed injector extends through an opening in the combustion liner. Each immersed injector is additively manufactured and made of a second material different from the first material.wherein each immersed injector is additively manufactured and made of a second material different than the first material), and a coupler fixing each AFS immersed injector in a respective opening in the combustion liner).

[0015] Another aspect of the present disclosure includes any of the preceding aspects and further includes a braze joint seal surrounding each AFS immersed injector at a surface of the combustion liner).

[0016] Another aspect of the disclosure includes any of the preceding aspects, wherein the coupler includes: a sleeve radially extending from an outer portion of the combustion liner at each opening in the combustion liner, each sleeve having an inner surface configured to mate with an outer surface of a respective AFS immersed injector; and a pin extending through an opening in the sleeve and an opening in a radially outer end of each AFS immersed injector.

[0017] Another aspect of the disclosure includes any of the preceding aspects, wherein the coupler includes a tack weld between a radially outer end of each AFS immersed injector and an outer portion of the combustion liner.

[0018] Another aspect of the disclosure includes any of the preceding aspects, where the coupler includes a threaded connection between each AFS immersed injector and the respective opening in the combustion liner.

[0019] Another aspect of the disclosure includes any of the preceding aspects, where each AFS immersed injector has a circular cross-sectional shape.

[0020] Another aspect of the disclosure includes any of the preceding aspects, where each AFS immersed injector has an airfoil cross-sectional shape.

[0021] Another aspect of the disclosure includes any of the preceding aspects, where each AFS immersed injector includes a fuel passage, an air passage therein, and a plurality of fuel-air nozzles spaced along a length thereof for supplying a fuel and air combustible mixture to the secondary combustion zone.

[0022] Another aspect of the present disclosure includes any of the preceding aspects and further includes a head end fuel nozzle assembly coupled to a forward end of the combustor body for supplying a fuel and air combustible mixture to the primary combustion zone.

[0023] Two or more aspects described in the present disclosure, including those described in this summary, may be combined to form implementations not specifically described herein. That is, all embodiments described herein can be combined with each other.

[0024] 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

[0025] These and other features of the present disclosure will be more readily understood from the following detailed description of the various aspects of the disclosure taken in conjunction with the accompanying drawings that depict various embodiments of the disclosure.

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[0026] Note that the drawings of the disclosure are not necessarily to scale. The drawings are intended to show only typical aspects of the disclosure and should not be regarded as limiting the scope of the disclosure. In the drawings, like numbering represents similar elements between the drawings.

DETAILED DESCRIPTION OF THE INVENTION

[0027] As a first issue, in order to clearly describe the present disclosure's subject matter, it is necessary to select specific terms when referring to and describing relevant machine components within an exemplary application of a turbomachine. In doing so, where possible, common industry terms are used and employed in a manner consistent with their accepted meanings. Unless otherwise noted, such terms should be given a broad interpretation 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 herein as a single component may include multiple components and may be referred to in another context. Alternatively, what may be described herein as including multiple components may be referred to elsewhere as a single component.

[0028] Further, some explanatory terms may be used regularly herein, and it should prove useful to define these terms at the beginning of this section. The convention and its definitions are as follows, unless otherwise specified. As used herein, "downstream" and "upstream" are terms indicating directions with respect to the flow of a fluid, e.g., the flow of a working fluid through a combustor of a turbomachine, or e.g., the flow of air through a combustor or coolant through one of the component systems of a turbomachine. 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" refer to directions without further specificity, 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.

[0029] The term "axial direction" refers to movement or position parallel to an axis, such as the axis of a combustor or a turbomachine. The term "radial direction: radial" refers to 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 the first component as being "radially inward" or "inner" of 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 the first component as being "radially outward" or "outer" of the second component. Finally, the term "circumferential direction" refers to 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 will be understood that such terms may be applied in relation to the axis of a combustor or the axis of a turbomachine.

[0030] 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.

[0031] 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, as used in this specification, the terms "comprising" and / or "comprises" specify the presence of the stated 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. "Any" or "optionally" means that the event described thereafter may or may not occur, or that the function described thereafter may or may not exist, and the description includes instances where the event occurs, instances where the function exists, instances where the event does not occur, or instances where the function does not exist.

[0032] 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, directly engaged to, connected to, coupled to, or attached 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 engaged to", "directly connected to", "directly coupled to", or "directly mounted on" another element or layer, 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., "directly between" for "between", "directly adjacent" for "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.

[0033] The disclosed embodiments provide a combustor for a gas turbine system. The combustor includes a combustor body that includes a combustion liner defining a primary combustion zone and a secondary combustion zone. The combustor body is additively manufactured and made of a first material. The combustor also includes a plurality of axial fuel stage (AFS) submerged injectors that extend radially into the combustion liner of the secondary combustion zone. Each AFS submerged injector extends through an opening in the combustion liner and is additively manufactured of a second material different from the first material. A coupler secures each AFS submerged injector to a respective opening in the combustion liner. The additively manufactured combustor body and AFS submerged injectors include a plurality of parallel sintered metal layers. By additive manufacturing, the number of parts within a particular combustor is reduced by as much as 70%, a low-cost material can be used for the combustor body, and a more expensive, high-temperature oxidation-resistant high-temperature gas path (HGP) material can be used for the AFS submerged injectors.

[0034] FIG. 1 shows a functional block diagram of an exemplary GT system 102 into which various embodiments of the combustor 100 of the present disclosure can be incorporated. As shown in FIG. 1, the GT system 102 generally includes an inlet section 110 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) 112 entering the GT system 102. The working fluid 112 flows into a compressor section 114, which gradually imparts kinetic energy to the working fluid 112 to produce compressed air 116 in a highly energized state. The compressed air 116 is mixed with fuel 118 from a fuel source 120 to form a combustible mixture, which is ignited and burned within one or more combustors 100 to produce high-temperature combustion gases 140.

[0035] The combustion gas 140 generates work by passing through a turbine 142 (e.g., an expansion turbine) of the turbine section. For example, the turbine 142 may be connected to a shaft 146 such that rotation of the turbine 142 drives the compressor 114 of the compressor section to generate compressed air 116. Alternatively, or additionally, the shaft 146 may connect the turbine 142 to a generator 148 to generate electricity. The exhaust gas 150 from the turbine 142 flows through an exhaust section 152 that connects the turbine 142 to an exhaust stack 154 downstream of the turbine 142. The exhaust section 152 may include, for example, a heat recovery steam generator (not shown) for scrubbing and extracting additional heat from the exhaust gas 150 before it is released to the environment.

[0036] In one embodiment, the GT system 102 may include a gas turbine engine model commercially available from GE Vernova of Cambridge, Massachusetts. The present disclosure is not limited to any particular GT system and may be embedded in relation to other engines, such as other HA, F, B, LM, GT, TM, and E-class engine models of GE Vernova, and engine models of 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.

[0037] FIG. 2 shows a cross-sectional view of a combustor 100 according to an embodiment of the disclosure. As shown in FIG. 2, the combustor 100 includes a combustor body 158 that contains a combustion gas 140 and includes a combustion liner 160 that conveys the combustion gas 140 to a turbine section that includes a turbine 142. As described herein, the combustion liner 160 may extend between a head end fuel nozzle assembly 166 and a rear frame 168. The combustion liner 160 includes a primary combustion zone 162 and a secondary combustion zone 164. More particularly, the combustion liner 160 defines a combustion chamber in which combustion occurs in the primary combustion zone 162 and the secondary combustion zone 164. A combustible mixture of fuel and air is burned to produce a high temperature and high pressure combustion gas 140.

[0038] The combustion liner 160 can have a cylindrical portion 172 and a tapered transition portion 174 integral with the cylindrical portion 172, i.e., form a unitary (or "unibody") structure. According to an embodiment of the present disclosure, the combustion liner 160 is additively manufactured using a first material. The first material may include any currently known or later developed combustion-resistant and oxidation-resistant material. The first material includes, but is not limited to: nickel-chromium-molybdenum-niobium alloy (NiCrMoNb) (e.g., Inconel 625 or Inconel 718), nickel-chromium-iron-molybdenum alloy (NiCrFeMo) (e.g., Hastelloy® X available from Haynes International, Inc.), or nickel-chromium-cobalt-molybdenum alloy (NiCrCoMo) (e.g., Haynes 282 or Haynes 233 available from Haynes International, Inc.), or nickel-chromium-cobalt titanium (NiCrCoTi) alloy (e.g., GTD262 developed by General Electric).

[0039] The combustor 100 may include a head end fuel nozzle assembly 166 (hereinafter "head end assembly 166") coupled to the front end of the combustor body 158 for supplying a fuel and air combustible mixture to the primary combustion zone 162. The head end fuel nozzle assembly 166 may include any currently known or later developed fuel nozzle assembly for supplying fuel 118 from an axially extending fuel nozzle 176 to the primary combustion zone 162. The head end assembly 166 generally includes at least one axially extending fuel nozzle 176 extending downstream from an end cover 170 and a cap assembly 178 extending radially and axially within the combustion liner 160 downstream from the end cover 170 and defining an upstream boundary of the combustion chamber.

[0040] The combustor 100 also includes a plurality of axially fuel stage (AFS) submerged injectors 180 that extend radially through the combustion liner 160 of the secondary combustion zone 164. FIG. 3 shows an end view of the AFS submerged injector 180 in the combustion liner 160. Referring to FIGS. 2 and 3, each AFS submerged injector 180 extends through an opening 182 in the combustion liner 160. Since the injectors extend into the secondary combustion zone 164 and the combustion gas 140 therein, they are called "immersed". Thus, they are immersed in the secondary combustion zone 164 and the combustion gas 140 is immersed therein. The AFS submerged injectors 180 may have different lengths (e.g., arranged alternately as shown in FIG. 3) or a common length (not shown).

[0041] Each AFS immersed injector 180 is additively manufactured and made of a second material different from the first material, i.e., of combustor body 158. The AFS immersed injector 180 is typically used in a high temperature gas path (HGP) component such as a turbine 142 blade or nozzle and may include a metal having a higher temperature and higher oxidation resistance than the first material used for the combustor body 158. The metal may be a pure metal or an alloy. The second material may include a non-reactive metal powder, i.e., a non-explosive or non-conductive powder, such as, but not limited to, a cobalt chromium molybdenum (CoCrMo) alloy, stainless steel, a nickel-chromium-molybdenum-niobium alloy (NiCrMoNb) (e.g., Inconel 625 or Inconel 718), a nickel-chromium-iron-molybdenum alloy (NiCrFeMo) (e.g., Hastelloy® X available from Haynes International, Inc., etc.), or a nickel-chromium-cobalt-molybdenum alloy (NiCrCoMo) (e.g., Haynes 282 available from Haynes International, Inc.). Other possibilities include, for example, Rene 108, CM 247, Mar M 247, and any precipitation hardenable (PH) nickel alloys, etc.

[0042] The combustor 100 also includes a coupler 190 that fixes each AFS immersion injector 180 to the respective opening 182 of the combustion liner 160. FIG. 4 shows a perspective view of the radially outer end of the coupler 190 according to one embodiment of the disclosure. In one embodiment, the coupler 190 includes a sleeve 192 that extends radially from the outer portion 194 of the combustion liner 160 at each opening 182 of the combustion liner 160. Each sleeve 192 may have an inner surface 195 configured to mate with the outer surface 196 of the respective AFS immersion injector 180, i.e., having the same cross-sectional shape. The sleeve 192 may be coextensive with the opening 182 of the combustion liner 160. The coupler 190 may further include a pin 198 that passes through an opening 200 in the sleeve 192 of the AFS immersion injector 180 and an opening 202 in the radially outer end 204. In this way, the pin 198 fixes the AFS immersion injector 180 to the opening 182. That is, the AFS immersion injector 180 cannot move relative to the opening 182. The pin 198 can be any form of mechanical fixing mechanism, such as a screw fastener, an interference pin, etc., and can fix the AFS immersion injector 180 in a predetermined position of the sleeve 192 and fix the opening 182 of the combustion liner 160.

[0043] The coupler 190 can take other forms. FIG. 5 shows a perspective view of the radially outer end of the coupler 190 according to another embodiment. In FIG. 5, the coupler 190 includes a threaded connection 210 with mating fasteners between each AFS immersion injector 180 and each opening 182 in the combustion liner 160, i.e., a threaded connection with mating fasteners. In this case, the AFS immersion injector 180 may have a radially outer end 204 (surface) with threads thereon configured to mate with the threads on the inner surface of the opening 182. The threaded arrangement can also be used with the sleeve 192 in the embodiment of FIG. 4 instead of the pin 198. The coupler 190 with a threaded connection may have any thread tolerance sufficient to prevent leakage from the high temperature gas path (HGP) in the combustion liner 160. FIG. 6 shows a perspective view of the radially outer end of the coupler 190 according to another embodiment. In FIG. 6, the coupler 190 includes a tack weld 212 between the radially outer end 204 of each AFS immersion injector 180 and the outer portion 194 of the combustion liner 160, i.e., around or surrounding the opening 182.

[0044] FIG. 7 shows a perspective view of one embodiment of the AFS immersion injector 180, and FIG. 8 shows a perspective view of another embodiment of the AFS immersion injector 180. In FIGS. 7 and 8, the radially inner end 214 of each AFS immersion injector 180 is shown in cross section, illustrating the internal configuration of the injector. The radially inner end 214 can have any type of terminal shape, for example, a rounded shape (see FIG. 3), a planar shape, etc. In FIG. 7, the AFS immersion injector 180 has a circular cross-sectional shape, and in FIG. 8, the AFS immersion injector 180 has an airfoil cross-sectional shape, for example, a symmetric airfoil. Other cross-sectional shapes are possible.

[0045] As shown in FIGS. 7 and 8, each AFS submerged injector 180 includes one or more fuel passages 220, one or more air passages 222, and a plurality of fuel-air nozzles 224 spaced along its length for supplying a fuel and air combustible mixture from the fuel passage 220 and the air passage 222 to the secondary combustion zone 164. Generally, compressed air 116 from the air passage 222 is directed from the fuel 118 through the fuel passage 220 and out of the nozzles 224 into the secondary combustion zone 164. As will be understood in the art, the arrangement of the passages 220, 222 and the nozzles 224 can take various forms depending on factors such as fuel properties (e.g., flow rate, combustibility, reactivity, pressure, temperature, etc.), physical properties of other combustors (e.g., combustion zone volume), and / or air properties (e.g., flow rate, pressure, temperature, etc.). Thus, it is emphasized that the passages and nozzle arrangements shown are merely exemplary.

[0046] Since possible arrangements are known in the art, no further details are provided so that the reader can focus on the significant portions of the disclosure. The foregoing fuel-air passage arrangement assumes pre-mixing of fuel and air. In other embodiments, it will be understood that either the fuel passage or the air passage can be omitted. For example, in the case of a highly reactive fuel (e.g., hydrogen), direct injection of the fuel into the combustion liner 160 can improve combustion without additional air input. In other cases, only air may be required to improve combustion. In these cases, either the fuel passage 220 or the air passage 222 is omitted and the nozzles 224 inject only air or fuel into the combustion liner 160. Alternatively, the fuel may be supplied from one set of nozzles or orifices and the air may be supplied from another set of nozzles or orifices proximate to the one set of nozzles or orifices.

[0047] FIG. 3 shows a circular fuel plenum 230 having a radially extending passage 232 for supplying fuel 118, e.g., natural gas or propane gas, to the AFS submerged injector 180. However, the fuel 118 can be delivered in any presently known or later developed manner. Compressed air 116 can also be supplied to the AFS submerged injector 180 in any presently known or later developed manner, e.g., through passage 234 at the radially outer end 204 of the injector 180 as shown in FIGS. 3 - 6.

[0048] In certain embodiments, as shown in FIGS. 7 and 8, the combustor 100 may also include a braze joint seal 238 that surrounds each AFS submerged injector 180 at the surface 242 (e.g., the inner surface) of the combustion liner 160. The brazing material may include any suitable material having the required wetting and environmental resistance in the secondary combustion zone 164. Alternatively, or in addition, a braze joint seal may be formed on the outer surface of the combustion liner 160 (e.g., similar to the tack welds 212 shown in FIG. 6).

[0049] Referring again to FIG. 2, the combustor body 158 may include an air flow path 240 provided in the combustion liner 160, or alternatively, may include a flow sleeve (not shown) spaced peripherally from a portion of the combustion liner 160. The air flow path 240 at least partially surrounds at least the cylindrical portion 172 of the combustion liner 160. The air flow path 240 routes compressed air 116 across the outer surface (cylindrical portion 172 and / or tapered transition portion 174) of the combustion liner 160. Further, the air flow path 240 may extend along the tapered transition portion 174 and route at least a portion of the compressed air 116 to one or more AFS immersion injectors 180 extending radially, where it may combine with fuel for combustion in a secondary combustion zone 164 downstream of the primary combustion zone 162. Further, as shown in FIG. 2, a fuel passage 244 extending along the combustion liner 160 (or along a fuel sleeve not shown, or within the fuel sleeve) can supply fuel from the fuel supply device 120 to the AFS immersion injectors 180. Note that the fuel for the head end assembly 166 and the AFS immersion injectors 180 may be different, for example, liquid fuel for the head end assembly 166 and gaseous fuel for the AFS immersion injectors 180.

[0050] The combustor 100 generally terminates at a point adjacent to the first stage 250 of the stationary nozzle 252 of the turbine 142. The first stage 250 of the stationary nozzle 252 at least partially defines a turbine inlet 254 for the turbine 142. As described above, the combustion liner 160 at least partially defines an HGP for routing combustion gases 140 from the primary combustion zone 162 and the secondary combustion zone 164 to the turbine inlet 254 of the turbine 142 during operation of the GT system 102.

[0051] During operation, compressed air 116 flows from compressor 114 and is routed through air flow path 240. A portion of the compressed air 116 is sent to the head end assembly 166 of combustor 100, where its direction is reversed and it is guided through axially extending fuel nozzle 176. The compressed air 116 is mixed with fuel to form a first combustible mixture, which is injected into primary combustion zone 162. The first combustible mixture is burned to produce combustion gas 140. A second portion of the compressed air 116 is routed through radially extending AFS immersion injector 180, where it can be mixed with fuel 118 from fuel passage 244 to form a second combustible mixture. The second combustible mixture is injected into the HGP through combustion liner 160. The second combustible mixture is at least partially mixed with combustion gas 140 and burned in secondary combustion zone 164. As described above, combustion liner 160 defines an HGP for routing combustion gas 140 from primary combustion zone 162 and secondary combustion zone 164 to turbine inlet 254 of turbine 142 during operation of GT system 102.

[0052] Combustor body 158 and each AFS immersion injector 180 may be additively manufactured using any known or later developed technique capable of forming a large monolithic body. As a result, as shown in FIG. 9, combustor body 158 includes a plurality of parallel sintered metal layers 260 of a first material, and as shown in FIG. 10, each AFS immersion injector 180 includes a plurality of parallel sintered metal layers 262 of a second material. FIG. 11 shows a schematic / block diagram of an exemplary computerized metal powder additive manufacturing system 310 (hereinafter "AM system 310") for generating combustor body 158 and / or AFS immersion injector 180, with only one layer thereof shown. The teachings of the disclosure are described in connection with combustor body 158 and / or AFS immersion injector 180 of a building using a plurality of melt beam sources 312, 314, 316, 318, but it is emphasized and will be readily recognized that the teachings of the disclosure are equally applicable to combustor body 158 and / or AFS immersion injector 180 of a building using any number of melt beam sources.

[0053] 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 perhaps other forms of additive manufacturing (i.e., those other than metal powder applications). The layers of the combustor body 158 and / or the AFS immersion injector 180 within the build platform 320 are shown as circular elements in FIG. 11. However, it is understood that the additive manufacturing process can be readily adapted to manufacture any shaped portion of the combustor body 158 and / or the AFS immersion injector 180 on the build platform 320.

[0054] The AM system 310 generally includes an additive manufacturing control system 330 (“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 series of computer-executable instructions or code 334 for generating the combustor body 158 and / or the AFS immersion injector 180. 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 as computer program code on a computer 336. 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.

[0055] 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 to and from the memory 338, the storage system (memory system) 340, the I / O device 350, and / or the AM printer 332. The bus 348 provides a communication link between the components 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.).

[0056] The computer 336 represents only various possible combinations of hardware and software. For example, the processor unit (PU) 344 may include a single processing unit or may be distributed over one or more locations, such as one or more processing units on a client and a server. Similarly, the memory 338 and / or the storage system 340 may be present 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.

[0057] As described above, the AM system 310, particularly the control system 330, executes code 334 to generate the combustor body 158 and / or the AFS immersion injector 180. 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 combustor body 158 and / or the AFS immersion injector 180 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 known currently or developed later that can operate the AM printer 332.

[0058] The set of computer-executable instructions 334O that define the combustor body 158 and / or the AFS immersion injector 180 may include an accurately defined 3D model of the combustor body 158 and / or the AFS immersion injector 180, and can be generated from any of a variety 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 code 334O representing the combustor body 158 and / or the AFS immersion injector 180 may be converted 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 Additive Manufacturing File (AMF) which is an American Society of Mechanical Engineers (ASME) standard in an Extensible Markup Language (XML)-based format designed to describe the shape and configuration of a three-dimensional object manufactured by any CAD software on any AM printer. The code 334O representing the combustor body 158 and / or the AFS immersion injector 180 may also be converted into and transmitted as a set of data signals, received as a set of data signals, converted into code, stored, etc., as required. 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 component designer, an intellectual property (IP) provider, a design company, an operator or owner of the AM system 310, or other sources.In any event, control system 330 executes code 334S and 334O, dividing combustor body 158 and / or AFS immersed injectors 180 into a series of thin slices assembled using AM printer 332 in successive layers of material。

[0059] AM printer 332 may include a sealed processing chamber 360 to provide a controlled atmosphere for printing the combustor body 158 and / or the AFS immersed injectors 180. The build platform 320 on which the combustor body 158 and / or the AFS immersed injectors 180 are constructed 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 combustor body 158 and / or the AFS immersed injectors 180. Although four melt beam sources 312, 314, 316, 318 are illustrated, it is emphasized that the teachings of the disclosure are applicable to systems using 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, where the metal powder can be exclusively melted, and may also include at least one overlapping field region where two or more sources can melt the metal powder. 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 code 334O。

[0060] For example, in FIG. 11, the melt beam source 312 creates a layer of the combustor body 158 (or the AFS immersion injector 180) using the melt beam 362 in one region, while the melt beam source 314 is shown to create a layer of the combustor body 158 (or the AFS immersion injector 180) using the melt beam 362' in another region. Each of the melt beam sources 312, 314, 316, 318 is calibrated in any currently known or later-developed method. That is, each of the melt beam sources 312, 314, 316, 318 correlates the expected position of its laser beam or electron beam relative to the build platform 320 with its actual position in order 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 can create melt beams, such as 362, 362', having the same cross-sectional area dimensions (e.g., shape and size during operation), output, and scan rate.

[0061] Continuing with FIG. 11, the applicator (or recoater blade) 370 may create a thin layer of the raw material 372 that spreads as a blank canvas on which each successive slice of the final combustor body 158 and / or the AFS immersion injector 180 is created. Various parts of the AM printer 332 may move to accommodate the addition of each new layer, e.g., the build platform 320 may lower 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-grain metal powder, the stock of which may be held in a chamber or powder reservoir 368 accessible by the applicator 370.

[0062] 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 in the processing chamber 360 from a source of the inert gas 376. In this case, the control system 330 may control a pump 380 and / or a 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 specific gas. The pump 380 may be provided regardless of the presence or absence of 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 the inert gas 376 can take the form of a material contained therein, such as a tank, a storage layer, or any conventional source for other supplies. Any sensor (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.

[0063] In operation, a build platform 320 with metal powder placed therein is provided in the processing chamber 360, and the control system 330 controls the flow of the mixed gas 374 in the processing chamber 360 from a source of the inert gas 376. The control system 330 also controls the AM printer 332, and in particular, controls the applicator 370 and the melting beam sources 312, 314, 316, 318 to sequentially melt the layers of metal powder on the build platform 320 to produce the combustor body 158 and / or the AFS immersion injector 180 in accordance with embodiments of the present disclosure. Although a specific 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.

[0064] As shown in FIG. 2, once the combustor body 158 and / or the AFS immersion injector 180 are formed, they may be assembled with other parts of the combustor 100 and / or connected to the turbine inlet 254. For example, the head end assembly 166 may be connected to the front end of the combustor body 158. The head end assembly 166 can be joined by any method known currently or developed later, such as welding or a fastener. Also, the turbine inlet 254 may be connected to the rear frame 168. The rear frame 168 can be joined to the turbine inlet 254 by any method known currently or developed later, such as welding or a fastener. The AFS injector 180 may be coupled to the coupler 190 such that, as illustrated in FIGS. 4 - 8 and as described above, the AFS injector 180 extends radially inward into the combustion chamber.

[0065] The present disclosure provides various technical and commercial advantages, examples of which are discussed herein. The additively manufactured combustor body reduces the cost of the combustor because there is no need to manufacture a very large number of parts and then assemble the parts. As a result, additive manufacturing reduces the number of parts in the final combustor by as much as 70%. Also, in additive manufacturing, a high-temperature gas path (HGP) material with high-temperature and high-oxidation resistance can be used for the AFS immersion injector, and a low-cost material can be used for the combustor body. Furthermore, additive manufacturing can form complex internal flow paths for air and fuel within the AFS immersion injector, facilitating the cooling and / or premixing of fuel and air.

[0066] The approximating language employed throughout this specification and the claims may be applied to modify any quantitative representation that could vary tolerably without resulting in a change in the basic function to which it pertains. Accordingly, values modified by terms such as "about," "approximately," "substantially," etc. are not limited to the specified exact values. In at least some instances, the approximating language may correspond to the precision of the equipment for measuring the value. Here, and throughout the specification and claims, range limitations may be combined and / or interchanged. Such ranges are identified and, unless the context or language indicates otherwise, include all sub-ranges contained 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 dependence on the precision of the equipment for measuring the value.

[0067] All structural, material, acts, and equivalents of all means or step-plus-function elements in the following claims are intended to include any structure, material, or act for performing the functions in combination with other specifically claimed claimed elements. The description of the present disclosure has been 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 were 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 uses contemplated.

Description of the Reference Numerals

[0068] 100: Combustor 102: GT System 110: Inlet Section 112: Working Fluid 114: Compressor Section 116: Compressed Air 118: Fuel 120: Fuel Supply Source 140: High-Temperature Combustion Gas 142: Turbine 146: Shaft 148: Generator 150: Exhaust Gas 152: Exhaust Section 154: Exhaust Stack 158: Combustor Body 160: Combustion Liner 162: Primary Combustion Zone 164: Secondary Combustion Zone 166: Head End Fuel Nozzle Assembly 168: Rear Frame 170: End Cover 172: Cylindrical Portion 174: Taper Transition Portion 176: Fuel Nozzle 178: Cap Assembly 180: Axial Fuel Stage Immersion Injector / AFS Immersion Injector 182: Opening 190: Coupler 192: Sleeve 194: Outer Portion 195: Inner Surface 196: Outer Surface 198: Pin 200: Opening 202: Opening 204: Radial Outer End 210: Threaded Connection 212: Tack Weld 214: Radial Inner End 220: Fuel Passage 222: Air Passage 224: Nozzle 230: Fuel Plenum 232, 234: Passage 238: Brazed Joint Seal 240: Air Flow Path 242: Surface 244: Fuel Passage 250: First Stage 252: Stationary Nozzle 254: Turbine Inlet 260: Multiple Parallel Sintered Metal Layers of the First Material 262: Multiple Parallel Sintered Metal Layers of the Second Material 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 370: Applicator / Re-Coating Blade 372: Raw Material 374: Gas Mixture 376: Inert Gas 380: Pump 382: Flow Valve System 386: Filter

Claims

Claim 1 A combustor (100) for a gas turbine system (102), comprising a combustor liner (160) including a primary combustion zone (162) and a secondary combustion zone (164), the combustor liner (160) being additively manufactured from a first material and a combustor body (158) being created; and a plurality of axially fuel stage (AFS) submerged injectors (180) extending radially in the combustor liner (160) of the secondary combustion zone (164), each AFS submerged injector (180) extending through an opening (182) of the combustor liner (160), each submerged injector (180) being additively manufactured from a second material different from the first material and a plurality of AFS submerged injectors (180) being created; and a coupler (190) fixing each AFS submerged injector (180) to a respective opening (182) of the combustor liner (160). Claim 2 The combustor (100) according to claim 1, further comprising a brazed joint seal (238) surrounding each AFS submerged injector (180) at a surface (242) of the combustor liner (160). Claim 3 The coupler (190) is a sleeve (192) extending radially from an outer portion (194) of the combustor liner (160) at each opening (182) of the combustor liner (160), each sleeve (192) having an inner surface (195) configured to fit with an outer surface (196) of each AFS submerged injector (180); and a pin (198) passing through an opening (200) of the sleeve (192) and an opening (202) of a radially outer end portion (204) of each AFS submerged injector (180). Claim 4 The combustor (100) according to claim 1, wherein the coupler (190) comprises a tack weld (212) between a radially outer end portion (204) of each AFS submerged injector (180) and the outer portion (194) of the combustor liner (160). Claim 5 The combustor (100) according to claim 1, wherein the coupler (190) comprises a threaded connection (206) between each AFS submerged injector (180) and each opening (182) in the combustor liner (160). Claim 6 The combustor (100) according to claim 1, wherein each AFS submerged injector (180) has a circular cross-sectional shape. Claim 7 The combustor (100) according to claim 1, wherein each AFS submerged injector (180) has an airfoil cross-sectional shape. Claim 8 Each AFS submerged injector (180) includes a fuel passage (220), an air passage (222), and a plurality of fuel-air nozzles (224) spaced along its length for supplying a fuel-air combustible mixture from the fuel passage (220) and the air passage (222) to the secondary combustion zone (164), the combustor (100) according to claim 1.

9. The combustor (100) according to claim 1, further comprising a head-end fuel nozzle assembly (166) coupled to the front end of the combustor body (158) for supplying a fuel-air combustible mixture to the primary combustion zone (162).

10. A gas turbine (GT) system (102), a compressor section (114), a combustion section operably coupled to the compressor section (114), a turbine section operably coupled to the combustion section, comprising, the combustion section including at least one combustor (100), at least one combustor (100) including a combustor body (158) including a combustion liner (160) having a primary combustion zone (162) and a secondary combustion zone (164), additively manufactured and made of a first material, a plurality of axially fuel staged (AFS) submerged injectors (180) radially extending into the combustion liner (160) of the secondary combustion zone (164), each AFS submerged injector (180) extending through an opening (182) of the combustion liner (160), each submerged injector (180) being additively manufactured and made of a second material different from the first material, a plurality of AFS submerged injectors (180), a coupler (190) for fixing each AFS submerged injector (180) to a respective opening (182) of the combustion liner (160), the GT system (102).

11. The GT system (102) according to claim 10, further comprising a brazed joint seal (238) surrounding each AFS submerged injector (180) at the surface (242) of the combustion liner (160).

12. The coupler (190) is a sleeve (192) radially extending from an outer portion (194) of the combustion liner (160) at each opening (182) of the combustion liner (160), each sleeve (192) having an inner surface (195) configured to fit with an outer surface (196) of each AFS submerged injector (180), the sleeve (192). The GT system (102) according to claim 10, comprising a pin (198) passing through an opening (200) of the sleeve (192) and an opening (202) at a radially outer end (204) of each AFS immersion injector (180).

13. The GT system (102) according to claim 10, wherein the coupler (190) includes a tack weld (212) between a radially outer end (204) of each AFS immersion injector (180) and an outer portion (194) of the combustion liner (160).

14. The GT system (102) according to claim 10, wherein the coupler (190) includes a threaded connection (206) between each AFS immersion injector (180) and each opening (182) in the combustion liner (160).

15. The GT system (102) according to claim 10, wherein each AFS immersion injector (180) has a circular cross-sectional shape.

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