Axial fuel stage immersed injector with internal cooling

Abstract

To provide an internal cooling system axial fuel injector.SOLUTION: An immersed axial fuel stage (AFS) injector (180) includes an injector body (188) configured to be positioned in a hot gas path within a combustion liner (160). The injector body (188) includes an outer wall (190) defining a hollow interior (192) and having film cooling holes (194) extending from the hollow interior (192) to an outside of the outer wall (190), and an inner wall (196) spaced from an inside of the outer wall (190) along at least part of a length of the outer wall (190), the inner wall (196) defining an air plenum (200) therein. Impingement cooling holes (194) in fluid communication with the air plenum (200) extend through the inner wall (196) along at least a portion of the inner wall (196) and the outer wall (190). A fuel passage (210) extends at least partially along the hollow interior (192) of the outer wall (190), and fuel nozzles (220) in fluid communication with the fuel passage (210) extend through to the outside of the outer wall (190).SELECTED DRAWING: Figure 2

Description

[Technical Field]

[0001] FIELD OF THE DISCLOSURE The present disclosure relates generally to turbomachine combustors, and more particularly to axial fuel stage immersed injectors with internal cooling. [Background technology]

[0002] A gas turbine system includes a combustion section including multiple combustors in which fuel is combusted to generate a flow of combustion gases that is converted to kinetic energy in a downstream turbine. Axial fuel stage (AFS) immersion injectors extend radially within the combustion liners of the combustors to combust fuel in a secondary combustion zone downstream of the primary combustion zone. The AFS immersion injectors are used to deliver more energetic combustion gases to the turbine, resulting in a more efficient combustor. Summary of the Invention

[0003] All aspects, examples and features described below can be combined in any way technically possible.

[0004] One aspect of the disclosure includes an axial fuel stage (AFS) immersion injector, an injector body configured to be positioned in a hot gas path within a combustion liner, the injector body comprising: an outer wall defining a hollow interior and having a plurality of film cooling holes extending from the hollow interior to an outside of the outer wall; and an inner wall spaced from an inside of the outer wall along at least part of a length of the outer wall, the inner wall defining an air plenum therein. a first plurality of impingement cooling holes extending through the inner wall along at least a first portion of the inner wall, the first plurality of impingement cooling holes being in fluid communication with the air plenum;the first plurality of impingement cooling holes in fluid communication with the air plenum, a fuel passage extending at least partially along the hollow interior of the outer wall, and a plurality of fuel nozzles extending through at least one of the inner wall and the outer wall to the outside of the outer wall, each fuel nozzle in fluid communication with the fuel passage.

[0005] Another aspect of the disclosure includes any of the preceding aspects, and further includes a coupler at a first end of the injector body, the coupler configured to couple the injector body in an opening of the combustion liner.

[0006] Another aspect of the disclosure includes any of the preceding aspects, wherein the air plenum includes a plurality of air plenums.

[0007] Another aspect of the present disclosure includes any of the preceding aspects, and further includes an intermediate wall extending from an inside of the outer wall to an outer surface of the inner wall along at least one second portion of the inner wall and the outer wall, the intermediate wall defines an air passage between the intermediate wall and the outer surface of the inner wall and a near-wall cooling passage between the intermediate wall and the inside of the outer wall, and the intermediate wall includes a second plurality of impingement cooling holes fluidly coupling the air passage and the near-wall cooling passage defined by the intermediate wall. wall, the air passage is in fluid communication with an outlet of an upstream one of the first plurality of impingement cooling holes and the second plurality of impingement cooling holesplurality of impingement cooling holes).

[0008] Another aspect of the present disclosure includes any of the preceding aspects, wherein the intermediate wall includes a plurality of intermediate walls spaced along a respective plurality of second portions of the inner wall and the outer wall.

[0009] Another aspect of the present disclosure includes any of the preceding aspects, wherein the air plenum is in fluid communication with a compressed air delivery plenum extending along an outside of the combustion liner.

[0010] Another aspect of the present disclosure includes a combustor for a gas turbine system, the combustor including a combustion liner and a plurality of axial fuel stage (AFS) immersed injectors extending radially into the combustion liner, each AFS immersed injector including an injector body, the injector body including an outer wall defining a hollow interior and having a plurality of film cooling holes extending from the hollow interior to an outside of the outer wall, and an inner wall spaced from an inside of the outer wall along at least part of a length of the outer wall, the inner wall defining an air plenum therein. a first plurality of impingement cooling holes extending through the inner wall along at least a first portion of the inner wall, the first plurality of impingement cooling holes being in fluid communication with the air plenum;the first plurality of impingement cooling holes in fluid communication with the air plenum, a fuel passage extending at least partially along the hollow interior of the outer wall, and a plurality of fuel nozzles extending through at least one of the inner wall and the outer wall to the outside of the outer wall, each fuel nozzle in fluid communication with the fuel passage.

[0011] Another aspect of the present disclosure includes any of the preceding aspects, and further includes a coupler at a first end of the injector body, the coupler configured to couple the injector body in an opening of the combustion liner.

[0012] Another aspect of the present disclosure includes any of the preceding aspects, wherein the air plenum includes a plurality of air plenums.

[0013] Another aspect of the present disclosure includes any of the preceding aspects, and further includes an intermediate wall extending from an inside of the outer wall to an outer surface of the inner wall along at least one second portion of the inner wall and the outer wall, the intermediate wall defines an air passage between the intermediate wall and the outer surface of the inner wall and a near-wall cooling passage between the intermediate wall and the inside of the outer wall, and the intermediate wall includes a second plurality of impingement cooling holes fluidly coupling the air passage and the near-wall cooling passage defined by the intermediate wall. wall, the air passage is in fluid communication with an outlet of an upstream one of the first plurality of impingement cooling holes and the second plurality of impingement cooling holesplurality of impingement cooling holes).

[0014] Another aspect of the present disclosure includes any of the preceding aspects, wherein the intermediate wall includes a plurality of intermediate walls spaced along a respective plurality of second portions of the inner wall and the outer wall.

[0015] Another aspect of the present disclosure includes any of the preceding aspects, wherein the air plenum is in fluid communication with a compressed air delivery plenum extending along an outside of the combustion liner.

[0016] 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 combustion liner for supplying a combustible mixture of fuel and air to the combustion liner.

[0017] Another aspect of the present disclosure includes a gas turbine (GT) system including 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 including a combustion liner and a plurality of axial fuel stage (AFS) immersed injectors extending radially into the combustion liner, each AFS immersed injector including an injector body, the injector body defining a hollow interior and having a plurality of film cooling holes extending from the hollow interior to an exterior of the outer wall. an inner wall spaced from an inside of the outer wall along at least part of a length of the outer wall, the inner wall defining an air plenum therein;the inner wall defining an air plenum therein; a first plurality of impingement cooling holes extending through the inner wall along at least a first portion of the inner wall, the first plurality of impingement cooling holes in fluid communication with the air plenum; a fuel passage extending at least partially along the hollow interior of the outer wall; and a plurality of fuel nozzles extending through at least one of the inner and outer walls to the outside of the outer wall, each fuel nozzle in fluid communication with the fuel passage. passage) and.

[0018] Another aspect of the present disclosure includes any of the preceding aspects, and further includes a coupler at a first end of the injector body, the coupler configured to couple the injector body in an opening of the combustion liner.

[0019] Another aspect of the present disclosure includes any of the preceding aspects, wherein the air plenum includes a plurality of air plenums.

[0020] Another aspect of the present disclosure includes any of the preceding aspects, and further includes an intermediate wall extending from an inside of the outer wall to an outer surface of the inner wall along at least one second portion of the inner wall and the outer wall, the intermediate wall defining an air passage between the intermediate wall and the outer surface of the inner wall and a near-wall cooling passage between the intermediate wall and the inside of the outer wall, and the intermediate wall including a second plurality of impingement cooling holes fluidly coupling the air passage and the near-wall cooling passage defined by the intermediate wall. wall, the air passage is in fluid communication with an outlet of an upstream one of the first plurality of impingement cooling holes and the second plurality of impingement cooling holesplurality of impingement cooling holes).

[0021] Another aspect of the present disclosure includes any of the preceding aspects, wherein the intermediate wall includes a plurality of intermediate walls spaced along a respective plurality of second portions of the inner wall and the outer wall.

[0022] Another aspect of the present disclosure includes any of the preceding aspects, wherein the air plenum is in fluid communication with a compressed air delivery plenum extending along an outside of the combustion liner.

[0023] 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 combustion liner for supplying a combustible mixture of fuel and air to the combustion liner.

[0024] Two or more aspects described in this disclosure, including those described in this Summary, may be combined to form embodiments not specifically described herein, i.e., all embodiments described herein may be combined with each other.

[0025] The details of one or more embodiments 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 explanation of the drawings]

[0026] 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 illustrating various embodiments of the present disclosure. [Figure 1] FIG. 1 illustrates a functional block diagram of an exemplary gas turbine system usable with a combustor having axially fuel staged (AFS) immersed injectors according to various embodiments of the present disclosure. [Figure 2] FIG. 1 is a cross-sectional side view of a portion of a combustor with an AFS immersion injector according to an embodiment of the present disclosure. [Figure 3] FIG. 1 illustrates an end view of multiple AFS immersion injectors in a combustion liner according to an embodiment of the present disclosure. [Figure 4] FIG. 4 is a cross-sectional view of an AFS immersion injector taken along view line AA of FIG. 3 according to an embodiment of the present disclosure. [Figure 5] FIG. 4 is a cross-sectional view of an AFS immersion injector taken along view line AA of FIG. 3 according to another embodiment of the present disclosure. [Figure 6] FIG. 4 is a cross-sectional view of an AFS immersion injector taken along line AA of FIG. 3 according to yet another embodiment of the present disclosure. [Figure 7] FIG. 10 is a schematic diagram of a radially inner end of an AFS injector according to an alternative embodiment of the present disclosure. [Figure 8] FIG. 1 illustrates a radially outward end perspective view of an AFS immersion injector according to an embodiment of the present disclosure. [Figure 9] FIG. 10 is a perspective view of the radially outer end of an AFS immersion injector according to another embodiment of the present disclosure. [Figure 10] FIG. 10 is a perspective view of the radially outer end of an AFS immersion injector according to another embodiment of the present disclosure. [Figure 11]FIG. 10 is a perspective view of the radially outer end of an AFS immersion injector according to yet another embodiment of the present disclosure. [Figure 12] FIG. 10 is a perspective view of the radially outer end of an AFS immersion injector according to an additional embodiment of the present disclosure. [Figure 13] FIG. 2 is a cross-sectional view of multiple parallel sintered metal layers of a combustor body according to an embodiment of the present disclosure. [Figure 14] FIG. 1 illustrates a cross-sectional view of multiple parallel sintered metal layers of an AFS immersion injector according to an embodiment of the present disclosure. [Figure 15] FIG. 1 is a schematic block diagram of an exemplary additive manufacturing system for additively manufacturing a combustor body or an AFS immersive injector in accordance with various embodiments of the present disclosure.

[0027] It should be noted that the drawings of the present disclosure are not necessarily to scale. The drawings are intended to depict only typical aspects of the present disclosure and therefore should not be considered limiting of the scope of the present disclosure. In the drawings, like numbers represent like elements between the drawings. DETAILED DESCRIPTION OF THE INVENTION

[0028] As an initial matter, a clear explanation of this disclosure requires the selection of specific terminology when referring to and describing relevant machine components in an exemplary turbomachine application. In this regard, common industry terminology will be used, where possible, and employed in a manner consistent with its common meaning. Unless otherwise specified, such terminology should be given a broad interpretation consistent with the context of this application and the appended claims. Those skilled in the art will recognize that particular components are often referred to using several different or overlapping terms. What is described herein as a single component may include and be referred to as being made up of multiple components in other contexts. Alternatively, what is described herein as including multiple components may be referred to elsewhere as a single component.

[0029] Additionally, several descriptive terms may be used periodically herein, and it may be helpful to define these terms at the beginning of this section. These terms and their definitions are as follows, unless otherwise specified: "Downstream" and "upstream," as used herein, are terms that indicate a direction relative to the flow of a fluid, such as a working fluid through a combustor of a turbomachine, or, for example, the flow of air through a combustor, or the flow of a coolant through one of the component systems of a turbomachine. The term "downstream" corresponds to the direction of fluid flow, and the term "upstream" refers to the opposite direction to the flow. Additionally, the terms "forward" and "aft," without further specification, refer to directions, with "forward" referring to the forward or compressor end of the turbomachine and "aft" referring to the aft or turbine end of the turbomachine.

[0030] The term “axial” refers to movement or position parallel to an axis, e.g., the axis of a combustor or turbomachine. The term “radial” refers to movement or position perpendicular to an axis, e.g., the axis of a combustor or turbomachine. In such cases, if a first component is closer to the axis than a second component, the first component is said to be “radially inward” or “inboard” of the second component. Conversely, if a first component is farther from the axis than a second component, the first component may be said to be “radially outward” or “outboard” of the second component. Finally, the term “circumferential” refers to movement or position around an axis, e.g., the circumferential inner surface of a combustion liner or the circumferential inner surface of a casing extending about a combustor. As indicated 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.

[0031] Furthermore, certain descriptive terms may be regularly used herein, as explained below: The terms "first," "second," and "third" may be used interchangeably to distinguish one component from another, and are not intended to imply the position or importance of the individual components.

[0032] The terms used herein are for the purpose of describing particular embodiments only and are not intended to be limiting of the disclosure. As used herein, the singular forms "a," "an," and "the" are intended to include the plural forms unless the context clearly dictates otherwise. It will be further understood that as used herein, the terms "comprises" and / or "comprising" specify the presence of stated features, integers, steps, operations, elements, and / or components, but do not exclude the presence or addition of one or more other features, integers, steps, operations, elements, components, and / or groups thereof. "Optional" or "optionally" means that the subsequently described event may or may not occur, or the subsequently described feature may or may not be present, and that the description includes instances in which the event occurs or the feature is present as well as instances in which the event does not occur or the feature is absent.

[0033] When an element or layer is referred to as "resting," "engaged," "connected," "coupled," or "attached" to another element or layer, it may be directly resting, engaged, connected, coupled, or attached to the other element or layer, or intervening elements or layers may be present. In contrast, when an element is referred to as being "directly on," "directly engaged," "directly connected," or "directly coupled" to another element or layer, there are no intervening elements or layers present. Other words used to describe relationships between elements should be interpreted similarly (e.g., "between" vs. "directly between," "adjacent" vs. "directly adjacent," etc.). As used herein, the term "and / or" includes any combination of one or more of the associated listed items. As used herein, the verb forms of "couple" and "mount" may be used interchangeably.

[0034] An embodiment of the present disclosure provides a submerged axial fuel stage (AFS) injector including an injector body configured to be positioned in a hot gas path within a combustion liner. The injector body includes an outer wall defining a hollow interior and having film cooling holes extending from the hollow interior to the exterior of the outer wall, and an inner wall spaced from the interior of the outer wall along at least a portion of the length of the outer wall, the inner wall defining an air plenum therein. Impingement cooling holes in fluid communication with the air plenum extend through the inner wall along at least a portion of the inner and outer walls. A fuel passage extends at least partially along the hollow interior of the outer wall, and a fuel nozzle in fluid communication with the fuel passage extends through the outer wall to the exterior. The AFS submerged injector can be additively manufactured. The AFS submerged injector provides robust internal cooling, such as near-wall cooling or impingement cooling, while allowing for the reuse of cooling air for combustion in the combustion liner.

[0035] FIG. 1 illustrates a functional block diagram of an exemplary GT system 102 that may incorporate various embodiments of a combustor 100 of the present disclosure, and FIG. 2 illustrates a cross-sectional view of a combustor 100 according to an embodiment of the present disclosure. As shown in FIG. 1 , the GT system 102 generally includes an inlet section 110 that may include a series of filters, cooling coils, moisture separators, and / or other devices to purify and otherwise condition a working fluid (e.g., air) 112 entering the GT system 102. The working fluid 112 flows to a compressor section, where a compressor 114 progressively imparts kinetic energy to the working fluid 112 to generate compressed air 116 (hereinafter “compressed air 116” or “air 116”) at a highly energized state. The compressed air 116 is mixed with, among other things, fuel 118 from a fuel supply 120 to form a combustible mixture within one or more combustors 100.

[0036] 2, the combustor 100 is at least partially surrounded by an outer casing 130, such as a compressor discharge casing and / or a turbine casing. The interior of the outer casing 130 is in fluid communication with a compressor discharge 132 of the compressor 114 and forms a compressed air supply 134. That is, the compressed air supply 134 includes compressed air 116 from the compressor discharge 132 of the compressor 114. However, the compressed air supply 134 may be any supply of compressed air 116 that may enter any type of opening or flow path within the combustor 100 for component cooling and / or combustion.

[0037] 1 , the combustion gases 140 flow through a turbine 142 (e.g., an expansion turbine) in a turbine section to produce work. For example, the turbine 142 may be connected to a shaft 146 such that rotation of the turbine 142 drives the compressor 114 in the compressor section to produce compressed air 116. Alternatively, or in addition, the shaft 146 may connect the turbine 142 to a generator 148 to produce electricity. Exhaust gases 150 from the turbine 142 flow 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) to scrub the exhaust gases 150 and further extract heat therefrom before discharging them to the environment.

[0038] In one embodiment, the GT system 102 may include a gas turbine engine commercially available from GE Vernova, Inc., Cambridge, Massachusetts. The present disclosure is not limited to any one particular GT system and may be adapted for use in connection with other 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 manufacturers. Furthermore, the present disclosure is not limited to a particular turbomachine and may be applied to, for example, steam turbines, jet engines, compressors, turbofans, etc.

[0039] As shown in FIG. 2 , the combustor 100 includes a combustor body 158 including a combustion liner 160 that contains and channels combustion gases 140 to a turbine section, including a turbine 142. As described herein, the combustion liner 160 may extend between a forward end fuel nozzle assembly 166 and an aft end frame 168. The combustion liner 160 includes a primary combustion zone 162 and a secondary combustion zone 164. More specifically, 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 combusted to produce high-temperature, high-pressure combustion gases 140. The combustion liner 160 may have a cylindrical portion 172 and a tapered transition portion 174 that is integral with the cylindrical portion 172, i.e., forms a unitary body (or “unibody”) structure. According to embodiments of the present disclosure, the combustion liner 160 and / or the combustor body 158 may be additively manufactured.

[0040] The combustor 100 may include a head-end fuel nozzle assembly 166 (hereinafter “head-end assembly 166”) coupled to a forward end 167 of the combustion liner 160 for delivering a combustible mixture of fuel and air to the primary combustion zone 162. The head-end fuel nozzle assembly 166 may include any now known or later developed fuel nozzle assembly for delivering fuel 118 to the primary combustion zone 162 from axially extending fuel nozzles 176. 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.

[0041] The combustor 100 also includes a plurality of axial fuel stage (AFS) immersed injectors 180 that extend radially within the combustion liner 160, e.g., within the secondary combustion zone 164. FIG. 3 illustrates an end view of the AFS immersed injectors 180 within the combustion liner 160. With reference to FIGS. 2 and 3 , each AFS immersed injector 180 extends through an opening 182 in the combustion liner 160. The injectors are referred to as “immersed” because they extend into the secondary combustion zone 164 and the combustion gases 140 therein. As will be described further, each AFS immersed injector 180 may be additively manufactured, for example, with the combustor body 158 or as a separate component coupled to the combustor body 158.

[0042] Each AFS immersion injector 180 may include an injector body 188. Figures 4-6 show cross-sectional views along view line AA of Figure 3, according to various embodiments of the present disclosure. As shown in Figures 4-6, the injector body 188 may include an outer wall 190 defining a hollow interior 192 and having a plurality of film-cooling holes 194 extending from the hollow interior 192 to the exterior of the outer wall 190. The exterior of the outer wall 190 includes the secondary combustion zone 164 within the combustion liner 160 (Figures 2-3). As further described, air 116 from within the injector body 188 passes through the film-cooling holes 194 to provide film cooling to the exterior of the outer wall 190, which subsequently aids in combustion within the secondary combustion zone 164. In one non-limiting example, the outer wall 190 may have a thickness in the range of 1.78 to 2.79 millimeters (mm) (0.07 to 0.11 inches). The film cooling holes 194 may have any size, number, location, and arrangement necessary to provide desired film cooling flow and / or combustion characteristics for a particular combustor 100. The film cooling holes 194 may be angled non-perpendicularly relative to the exterior (outer surface) of the outer wall 190, for example, to direct the air 116 in the direction of flow of the combustion gases 140 (arrows in FIGS. 4-6) within the combustion liner 160 (FIGS. 2-3). However, it should be noted that the film cooling holes 194 may be angled differently relative to the exterior of the outer wall 190 depending on their location within the outer wall 190.

[0043] The injector body 188 may also include an inner wall 196 spaced apart from an interior side 198 of the outer wall 190 along at least a portion of the length of the outer wall 190, i.e., into and out of the page of Figures 4-6. The inner wall 196 defines an air plenum 200 therein. The air plenum 200 may include one or more air plenums, which may include any form of air passage or cavity defined within the inner wall 196 by, for example, any number of longitudinally extending walls 202 (shown in dashed lines in Figure 4 and solid lines in Figure 6). Figures 4 and 6 illustrate embodiments including multiple air plenums 200. In Figure 4, for example, up to four air plenums 200 are provided (via three walls 202). Figure 6 illustrates two air plenums 200 separated by a single wall 202. In contrast, in Figure 5, one large air plenum 200 is used. It is emphasized that any number and size of air plenums 200 may be used.

[0044] As will be described further, each air plenum 200 is in fluid communication with the compressed air supply 134. In certain embodiments, as will be described further, the air plenum(s) 200 may extend through the combustion liner 160 and open at an end (i.e., a radially outer end) of the injector body 188 that is in fluid communication with the compressed air supply 134. In an alternative embodiment, shown in FIGS. 3 and 9, the AFS injector 180 may also include at least one air plenum 200 in fluid communication with a compressed air delivery plenum 208 that extends along the outside of the combustion liner 160. The compressed air supply plenum 208 is in fluid communication with the air supply 134, for example, via an opening therein or any necessary routing conduits.

[0045] The inner wall 196 may extend the entire length of the injector body 188 and the outer wall 190 (into and out of the page in Figures 4-6). Alternatively, the inner wall 196 may extend only partially along the length of the outer wall 190, as shown in the schematic side view of the radially outer end of the injector body 188 in Figure 7. In one non-limiting example, the inner wall 196 may have an inner width W in the range of 12.70 to 19.05 millimeters (mm) (0.5 to 0.75 inches).

[0046] The inner wall 196 also includes a plurality of impingement cooling holes 204 extending therethrough along at least a first portion thereof for directing cooling air along a corresponding first portion of the outer wall 190. The impingement cooling holes 204 are in fluid communication with the air plenum 200, thereby directing the compressed air 116 against the inside 198 of the outer wall 190 to cool the outer wall 190. The number, size, location, and arrangement of the impingement cooling holes 204 may be user-defined based on, for example, the fuel used, the properties of the air 116, the size of the injector body 188 and / or the combustor 100, the operating temperature, and the material of the injector body 188.

[0047] The injector body 188 also includes a fuel passage 210 that extends at least partially along the hollow interior 192 of the outer wall 190. The fuel passage 210 within the injector body 188 is in fluid communication with the fuel supply 120, for example, via a fuel conduit 286 (FIGS. 2-3) that extends along the outside of the combustion liner 160 and / or a fuel conduit 286 (FIGS. 2-3) that is integrated into the combustion liner 160. Any form of fuel 118 may be directed within the fuel passage 210 within the injector body 188. The fuel passage 210 is shown in FIGS. 4-5 as extending within the hollow interior 192 and the inner wall 196. However, in other embodiments, the fuel passage 210 may be integrated into or formed within the inner wall 196, as shown in FIG. 6.

[0048] The injector body 188 also includes a plurality of fuel nozzles 220 that extend through at least one of the inner wall 196 and the outer wall 190 to the exterior of the outer wall 190, i.e., to the secondary combustion zone 164. Each fuel nozzle 220 is in fluid communication with a fuel passage 210. The fuel nozzles 220 may be spaced longitudinally of the injector body in any manner, such as uniformly, in groups, or non-uniformly. The fuel nozzles 220 may be spaced longitudinally along a trailing edge 222 of the injector body 188, which has an airfoil cross-sectional shape. The fuel nozzles 220 may have any configuration to provide desired fuel and air mixing and / or distribution.

[0049] 4 , the first portions (not labeled) of the inner and outer walls 196, 190 actually include the entirety of each wall except where the fuel nozzles 220 extend therethrough. In contrast, in other embodiments, such as those shown in FIGS. 5 and 6 , the first portions 206 of the inner and outer walls 196, 190 include only a portion of each wall 196, 190. In the example of FIG. 5 , the first portions 206 extend from approximately the 8 o'clock position to approximately the 1 o'clock position of the inner and outer walls 196, 190, while in the example of FIG. 6 , the first portions 206 extend from approximately the 6 o'clock position to approximately the 12 o'clock position of the inner and outer walls 196, 190. In the example of Figure 5, the first portion 206 has an airfoil cross-sectional shape and encompasses the leading edge of the injector body 188 including a relatively small area on one side of the injector body 188 and a relatively long area on the opposite side of the injector body 188. In the example of Figure 6, the first portion 206 has an airfoil cross-sectional shape and encompasses the leading edge of the injector body 188 including most of the area on both sides of the injector body 188. As shown in the example of Figure 6, the first portion 206 encompasses approximately the same area on each side of the injector body 188.

[0050] As shown in Figures 5 and 6, outside of the first portion 206, the injector body 188 also includes one or more intermediate walls 226 extending from the inside 198 of the outer wall 190 to the outer surface 228 of the inner wall 196 along at least one second portion 230 of the inner wall 196 and the outer wall 190. In certain embodiments, the intermediate walls 226 may include a plurality of intermediate walls 226 spaced apart along the plurality of second portions 230 of the inner wall 196 and the outer wall 190, respectively. Figure 5 shows six second portions 230A-F each having an intermediate wall 226, and Figure 6 shows two second portions 230G-H each having an intermediate wall 226.

[0051] The intermediate walls 226 may extend in a curved manner from the inside 198 of the outer wall 190 to the outer surface 228 of the inner wall 196. As shown for clarity in Figures 5 and 6 only with respect to a second portion 230A or 230G, respectively, each intermediate wall 226 defines an air passage 232 between the intermediate wall 226 and the outer surface 228 of the inner wall 196, and a near-wall cooling passage 234 between the intermediate wall 226 and the inside 198 of the outer wall 190. The intermediate walls 226 may extend any length along the walls 190, 196. Where an end 240 of the intermediate wall 226 abuts an adjacent inner wall 196, the inner wall 196 may include a curved portion 242 thereat.

[0052] The intermediate wall 226 includes a second plurality of impingement cooling holes 244 defined therein that fluidly connect the air passages 232 and the near-wall cooling passages 234. Thus, each second portion 230 provides the intermediate wall 226 with impingement cooling of the inner side 198 of the outer wall 190 and near-wall cooling of the outer wall 190 using the near-wall cooling passages 234. As shown, each air passage 232 in the second portion 230 is in fluid communication with an outlet of an upstream one of the first plurality of impingement cooling holes 204 (in the inner wall 196 adjacent the respective air passage 232) or the second plurality of impingement cooling holes 244 (in the intermediate wall 226 adjacent the respective air passage 232). Thus, air 116 from the air plenum 200 (also indicated by arrows in FIGS. 4-6 ) passes through the first plurality of impingement cooling holes 204 in the inner wall 196. A portion of the air 116 then passes through film cooling holes 194 in the outer wall to secondary combustion zone 164, and a portion of the air 116 passes to air passages 232 in a second downstream portion 230 of inner wall 196, including intermediate wall 226, and outer wall 190. A portion of the air 116 in air passages 232 passes through a second plurality of impingement cooling holes 244 in intermediate wall 226 to near-wall cooling passages 234. A portion of the air 116 impinges on an inner side 198 of outer wall 190 and / or flows along outer wall 190 in near-wall cooling passages 234. The air 116 then either escapes completely through the film cooling holes 194 in the outer wall 190 into the secondary combustion zone 164, or, if there is another (adjacent) downstream second portion 230, a portion of the air 116 escapes through the film cooling holes 194 in the outer wall 190 into the secondary combustion zone 164, and another portion of the air 116 passes through the adjacent downstream second portion 230 via a passage 298 (e.g., from second portion 230A to adjacent second portion 230B, as shown in FIG. 5).

[0053] FIG. 8 illustrates a perspective view of the radially outer end of the injector body 188 of the AFS immersion injector 180 in accordance with an embodiment of the present disclosure. As previously described, each air plenum 200 of the injector body 188 is in fluid communication with a compressed air supply 134, which is supplied with compressed air 116 from the compressor discharge 132 of the compressor 114. The compressed air 116 may also be supplied to the AFS immersion injector 180 in any manner now known or later developed. In the particular embodiment illustrated in FIG. 8 , the air plenum(s) 200 may extend through the combustion liner 160 and open at an end 240 thereof in fluid communication with the compressed air supply 134. In an alternative embodiment illustrated in FIGS. 3 and 9 , the AFS injector 180 may also include an air plenum 200 in fluid communication with an air supply plenum defined by a shroud element 208 extending along the outside of the combustion liner 160. A compressed air supply plenum-defining shroud element 208 fluidly connects the compressed air supply 134 to the air plenum(s) 200 within each AFS submerged injector 180 .

[0054] Each AFS immersion injector 180 may also include a coupler 250 at a first end of the injector body 188 configured to couple the injector body to an opening 182 in the combustion liner 160. FIG. 10 illustrates a radially outer end perspective view of the coupler 250 according to one embodiment of the present disclosure. In a particular embodiment, the coupler 250 includes a sleeve 252 extending radially from an outer portion 255 of the combustion liner 160 at each opening 182 in the combustion liner 160. Each sleeve 252 may have an inner surface 256 configured to mate with an outer surface 258 of the respective AFS immersion injector 180, i.e., may have the same cross-sectional shape. The sleeve 252 may be identical to the opening 182 in the combustion liner 160. The coupler 250 may further include a pin 260 extending through an opening 262 in the sleeve 252 and an opening 263 at a radially outer end 264 of the AFS immersion injector 180. In this manner, the pin 260 secures the AFS immersion injector 180 in the opening 182. That is, the AFS immersion injector 180 cannot move relative to the opening 182. The pin 260 may be any type of mechanical fastening mechanism capable of securing the AFS immersion injector 180 in place in the sleeve 252 and opening 182 of the combustion liner 160, such as a threaded fastener, an interference fit pin, or the like.

[0055] The coupler 250 may take other forms. FIG. 11 is a perspective view of the radially outer end of an AFS immersion injector 180 having a coupler 250 according to another embodiment. In FIG. 11, the coupler 250 includes a threaded connection 270 between each AFS immersion injector 180 and a respective opening 182 in the combustion liner 160, i.e., with a mating threaded fastener. In this case, the AFS immersion injector 180 may have a circular cross-section (e.g., at least its radially outer end 264), and the radially outer end 264 (surface) may be provided with threads configured to mate with threads on the inner surface of the opening 182. A threaded arrangement may also be used with the sleeve 252 in the embodiment of FIG. 10 rather than the pin 260, i.e., at least the radially outer end 264 of the injector body 188 has a circular cross-section. Coupler 250, having a threaded connection, can have any necessary thread tolerances to prevent leakage from the hot gas path (HGP) within combustion liner 160. Figures 8, 9, and 12 are perspective views of coupler 250 according to alternative embodiments. In these embodiments, coupler 250 includes a tack weld 272 between the radially outer end 264 of each AFS immersion injector 180 and the outer portion 255 of combustion liner 160, i.e., at or around opening 182.

[0056] The radially inner end of the AFS immersion injector 180 can have any desired configuration, for example, rounded, conical, etc. In Figures 4-6, the AFS immersion injector 180 has a symmetrical airfoil cross-sectional shape. Other cross-sectional shapes, such as circular, are also possible.

[0057] The arrangements of the impingement holes 204, 244, film cooling holes 194, intermediate wall 226, air plenum 200, air passages 232, near-wall cooling passages 234, fuel passages 210, and nozzles 220 can take a variety of alternative forms other than those shown, depending on many factors, such as, but not limited to, fuel characteristics (e.g., flow rate, combustibility, reactivity, pressure, temperature, etc.), other combustor physical and operational characteristics (e.g., combustion zone volume), and / or air characteristics (e.g., flow rate, pressure, temperature, etc.). Accordingly, it is emphasized that the arrangements shown herein are merely exemplary. Furthermore, while FIG. 3 depicts a circular fuel plenum 280 having radially extending passages 282 for supplying fuel 118 to the fuel passages 210 in each injector body 188 of the AFS immersion injector 180, other arrangements are possible. That is, the fuel 118 can be supplied to the fuel passages 210 in the injector body 188 in any manner now known or later developed.

[0058] 2 , the combustor body 158 also includes an airflow passage 284 provided in the combustion liner 160, or alternatively, an airflow passage 284 provided by a flow sleeve (not shown) spaced from and surrounding a portion of the combustion liner 160. The airflow passage 284 at least partially surrounds at least the cylindrical portion 172 of the combustion liner 160. The airflow passage 284 channels the compressed air 116 across the outer surface (cylindrical portion 172 and / or tapered transition portion 174) of the combustion liner 160. Additionally, the airflow passage 284 may direct at least a portion of the compressed air 116 to one or more radially extending AFS immersion injectors 180 for combination with the fuel 118 for combustion in a secondary combustion zone 164 downstream of the primary combustion zone 162. Additionally, as shown in FIG. 2 , a fuel conduit 286 extending along or within the combustion liner 160 (or fuel sleeve, not shown) can supply fuel 118 from the fuel supply 120 to the AFS immersion injector 180, i.e., to the fuel passage 210 within the injector body 188.

[0059] The combustor 100 generally terminates adjacent a first stage 288 of a static nozzle 290 of the turbine 142. The first stage 288 of the static nozzle 290 at least partially defines a turbine inlet 254 to the turbine 142. As previously mentioned, the combustion liner 160 at least partially defines an HGP for channeling the combustion gases 140 from the primary combustion zone 162 and secondary combustion zone 164 to the turbine inlet 254 of the turbine 142 during operation of the GT system 102.

[0060] During operation, compressed air 116 flows from the compressor 114 into the outer casing 130 surrounding the combustors 100 and passes through the fluid flowpath of each combustor 100. A portion of the compressed air 116 is routed to the head end assembly 166 of the combustor 100, where it reverses direction and is directed to the axially extending fuel nozzles 176. The compressed air 116 mixes with fuel 118 to form a first combustible mixture that is injected into the primary combustion zone 162. The first combustible mixture combusts to generate combustion gases 140. A second portion of the compressed air 116 passes through the radially extending AFS immersion injectors 180, where it mixes with the fuel 118 provided by the fuel conduits 286 and is delivered through the internal fuel passages 210 to form a second combustible mixture. In either case, the second combustible mixture is injected into the combustion liner 160 and into the HGP. The second combustible mixture at least partially mixes with the combustion gases 140 and is combusted in the secondary combustion zone 164. As previously mentioned, the combustion liner 160 defines an HGP for directing the 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.

[0061] With respect to the flow of air 116 within the AFS immersion injector 180, as indicated by the arrows of the air 116 in FIGS. 4-6 , a second portion of the compressed air 116 enters air plenum(s) 200 (exiting the page of FIGS. 4-6 ) and passes through a plurality of impingement cooling holes 204 defined through the inner wall 196, i.e., any first portion(s) 206 within the injector body 188. More specifically, at the inner wall 196 and the first portion 206 of the outer wall 190, the air 116 impinges on and cools the inside 198 of the outer wall 190, after which the first portion of the flow passes through the film cooling holes 194 and exits into the secondary combustion zone 164 within the combustion liner 160. If a downstream second portion 230 is present (as is the case in FIGS. 5 and 6 ), the second portion of the flow travels to the downstream second portion 230. The size of each flow portion can be controlled by, among other things, the size and number of film cooling holes 194 and the size of the passages 298 between the first portion 206 and the second portion 230 or between the second portions 230. For any second portion of the inner wall 196 and the outer wall 190, e.g., 230A-F in FIG. 5 , a second portion of the flow of air 116 enters a respective air passage 232 between the mid-wall 226 and the inner wall 196 in the respective second portion 230. The air 116 then passes through impingement cooling holes 244 in the respective mid-wall 226 to cool the interior 198 of the outer wall 190 in the respective second portion 230. The second portion of the flow of air 116 then either exits through the film cooling holes 194 to the secondary combustion zone 164 in the combustion liner 160 or splits again to flow to a subsequent second portion, e.g., 230B or 230D-F in FIG. 5 . For each subsequent or downstream second portion 230 of the inner and outer walls 190, 196, the process of impingement cooling the inner side 198 of the outer wall 190 or passing through the subsequent air passages 232 is repeated until all of the air 116 has exited the secondary combustion zone 164, providing a layer of film cooling around the AFS immersion injectors 180 and contributing to the second combustible mixture.

[0062] The combustor body 158 and each injector body 188 of the AFS immersed injector 180 may be additively manufactured using any now known or later developed technique capable of forming a large, monolithic body. In certain embodiments, as shown in FIG. 13 , the combustor body 158 includes multiple parallel sintered metal layers 294 of a first material, and as shown in FIG. 14 , each AFS immersed injector 180 includes multiple parallel sintered metal layers 296 of a second material. The first material for the combustor body 158 may include any now known or later developed combustion- and oxidation-resistant material. The first material may be 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 Qualcomm, Inc.), a nickel-chromium-cobalt-molybdenum alloy (NiCrCoMo) (e.g., Haynes 233 or Haynes 282 available from Haynes International, Inc.), or a nickel-chromium-cobalt-titanium (NiCrCoTi) alloy (e.g., GTD 262 developed by General Electric Company). The AFS immersion injector 180, i.e., the injector body 188, may comprise a metal typically used in hot gas path (HGP) components, such as the blades or nozzles of the turbine 142, that has higher oxidation resistance at high temperatures than the first material used in the combustor body 158. The metal may be a pure metal or an alloy.

[0063] The second material used for the combustor body 158 can be made from non-reactive metal powders, i.e., non-explosive or non-conductive powders, such as, but not limited to, cobalt chromium molybdenum (CoCrMo) alloy, stainless steel, 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 available from Haynes International, Inc.). Other possibilities include, for example, Rene 108, CM 247, Mar M 247, and any precipitation hardenable (PH) nickel alloy.

[0064] 15 is a schematic / block diagram of an exemplary computerized metal powder additive manufacturing system 310 (hereinafter “AM system 310”) for producing the combustor body 158 and / or the AFS immersed injector 180, of which only a single layer is shown. The combustor body 158 and the AFS immersed injector 180 can be manufactured separately or as an integral unit piece. It is emphasized, and will be readily recognized, that while the teachings of the present disclosure are described in connection with constructing the combustor body 158 and / or the AFS immersed injector 180 using multiple melt beam sources 312, 314, 316, 318, the teachings of the present disclosure are similarly applicable to constructing the combustor body 158 and / or the AFS immersed injector 180 using any number of melt beam sources.

[0065] In this example, AM system 310 is configured for direct metal laser melting (DMLM). It is understood that the general teachings of the present disclosure are similarly applicable to other forms of metal powder additive manufacturing, such as but not limited to selective laser melting (SLM), and possibly other forms of additive manufacturing (i.e., other than metal powder applications). While the layers of combustor body 158 and / or AFS immersed injector 180 in build platform 320 are illustrated as circular elements in FIG. 15 , it is understood that the additive manufacturing process can be readily adapted to produce any shaped portion of combustor body 158 and / or AFS immersed injector 180 on build platform 320.

[0066] The AM system 310 generally includes an additive manufacturing control system 330 (“control system”) and an AM printer 332. As will be described, the control system 330 executes a set of computer-executable instructions or code 334 to generate the combustor body 158 and / or the AFS immersion injector 180 using multiple melt beam sources 312, 314, 316, and 318. In the illustrated example, the four melt beam sources may include four lasers. However, the teachings of the present disclosure are applicable to any melt beam source, such as, for example, an electron beam, a laser, etc. The control system 330 is shown implemented on a computer 336 as computer program code. To this extent, the computer 336 is shown to include a memory 338 and / or storage system 340, a processor unit (PU) 4, an input / output (I / O) interface 346, and a bus 348. Additionally, the computer 336 is shown in communication with an external I / O device / resource 350.

[0067] Generally, processor unit (PU) 344 executes computer program code 334 stored in memory 338 and / or storage system 340. While executing computer program code 334, processor unit (PU) 344 can read and / or write data from memory 338, storage system 340, I / O devices 350, and / or AM printer 332. Bus 348 provides a communication link between each component within computer 336, and I / O devices 350 can be any device (e.g., keyboard, pointing device, display, etc.) that allows a user to interact with computer 336.

[0068] Computer 336 is merely representative of various possible combinations of hardware and software. For example, processor unit (PU) 344 may consist of a single processing unit or may be distributed across one or more processing units at one or more locations, e.g., a client and a server. Similarly, memory 338 and / or storage system 340 may reside at one or more physical locations. Memory 338 and / or storage system 340 may be comprised of 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. Computer 336 may consist of any type of computing device, such as an industrial controller, a network server, a desktop computer, a laptop, a handheld device, etc.

[0069] As previously described, the AM system 310, and in particular the control system 330, executes code 334 to generate the combustor body 158 and / or the AFS immersive injector 180. The code 334 may 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 immersive injector 180, that is 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 may include any now known or later-developed software code capable of operating the AM printer 332.

[0070] The set of computer-executable instructions 334O defining the combustor body 158 and / or the AFS immersive injector 180 may include a precisely defined 3D model of the combustor body 158 and / or the AFS immersive injector 180 and may be generated from any of a wide variety of well-known computer-aided design (CAD) software systems, such as AutoCAD®, TurboCAD®, DesignCAD 3D Max, etc. In this regard, the code 334O may include any now known or later developed file format. Furthermore, the code 334O representing the combustor body 158 and / or the AFS immersive injector 180 may be converted between different formats. For example, the code 334O may include a Standard Tessellation Language (STL) file created for 3D Systems' stereolithography CAD program or an Additive Manufacturing File (AMF), an American Society of Mechanical Engineers (ASME) standard that is an Extensible Markup Language (XML)-based format designed to allow any CAD software to describe the shape and configuration of any three-dimensional object to be manufactured by any AM printer. Code 334O representing combustor body 158 and / or AFS immersive injector 180 may also be converted to a set of data signals and transmitted, received as a set of data signals, converted to code, stored, etc., as needed. Code 334O may be configured to enable the formation of boundaries and interior sections in overlapping field regions, as will now be described, according to embodiments of the present disclosure. In either case, code 334O may be input to AM system 310 and may come from a part designer, intellectual property (IP) provider, design firm, operator or owner of AM system 310, or other source. In either case, control system 330 executes code 334S and 334O to divide combustor body 158 and / or AFS immersive injector 180 into a series of slices that are assembled using AM printer 332 with successive layers of material.

[0071] The AM printer 332 may include a process chamber 360 that is sealed to provide a controlled atmosphere for printing the combustor body 158 and / or AFS immersion injector 180. A build platform 320, upon which the combustor body 158 and / or AFS immersion injector 180 are / is built, is disposed within the process chamber 360. Multiple melt beam sources 312, 314, 316, 318 are configured to melt layers of metal powder on the build platform 320 to produce the combustor body 158 and / or AFS immersion injector 180. While four melt beam sources 312, 314, 316, 318 are illustrated, it is emphasized that the teachings of the present disclosure are applicable to systems employing any number of sources, e.g., one, two, three, or five or more sources. As understood in the art, each melting beam source 312, 314, 316, 318 can have a field that includes a non-overlapping field region where it is solely capable of melting the metal powder, or two or more sources can include at least one overlapping field region where it is capable of melting the metal powder. In this regard, each melting beam source 312, 314, 316, 318 can generate a melting beam that melts the particles for each slice, as defined by reference numeral 334O.

[0072] 15 , melt beam source 312 is shown forming a layer of combustor body 158 (or AFS immersion injector 180) in one region using melt beam 362, while melt beam source 314 is shown forming a layer of combustor body 158 (or AFS immersion injector 180) in another region using melt beam 362′. Each melt beam source 312, 314, 316, 318 is calibrated by any now known or later developed method. That is, each melt beam source 312, 314, 316, 318 has the expected position of its laser or electron beam relative to build platform 320 correlated with its actual position to provide individual positional corrections (not shown) to ensure its individual accuracy. In one embodiment, each of the multiple melt beam sources 312, 314, 316, 318 can generate a melt beam, eg, 362, 362', having the same cross-sectional dimensions (eg, shape and size during operation), power, and scan speed.

[0073] 15 , an applicator (or re-coater blade) 370 can create a thin layer of feedstock 372 that is laid down as a blank canvas upon which each successive slice of the final combustor body 158 and / or AFS immersion injector 180 is created. Various parts of the AM printer 332 may move to accommodate the addition of each new layer; for example, after each layer, the build platform 320 may lower and / or the chamber 360 and / or applicator 370 may raise. The process may use a different raw material in the form of a stock, fine-grained metal powder that may be held in a chamber or powder reservoir 368 accessible by the applicator 370.

[0074] The process 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 a gas mixture 374 into the process chamber 360 from an inert gas source 376. In this case, the control system 330 can control a pump 380 and / or an inert gas flow valve system 382 to control the content of the gas mixture 374. The flow valve system 382 can include one or more computer-controllable valves, flow sensors, temperature sensors, pressure sensors, etc., that can precisely control the flow of specific gases. The pump 380 can 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 before being introduced into the process chamber 360. The source of the inert gas 376 can take the form of any conventional source for the material contained therein, such as a tank, reservoir, or other source. Any sensors (not shown) necessary to measure the gas mixture 374 may be provided. The gas mixture 374 may be filtered using a filter 386 in a conventional manner.

[0075] During operation, build platform 320 loaded with metal powder is provided within process chamber 360, and control system 330 controls the flow of gas mixture 374 within process chamber 360 from inert gas source 376. Control system 330 also controls AM printer 332, particularly applicator 370 and melt beam sources 312, 314, 316, 318, to sequentially melt layers of metal powder on build platform 320 to generate combustor body 158 and / or AFS immersion injector 180 in accordance with embodiments of the present disclosure. While a particular AM system 310 is described herein, it is emphasized that the teachings of the present disclosure are not limited to any particular additive manufacturing system or method.

[0076] Once the combustor body 158 and / or AFS submerged injector 180 are formed, they may be assembled with other components of the combustor 100 and / or with the turbine inlet 254, as shown in FIG. 2 . For example, the head end assembly 166 may be coupled to the forward end of the combustor body 158. The head end assembly 166 may be coupled by any now known or later developed method, such as welding or fasteners. Additionally, the turbine inlet 254 may be coupled to the aft frame 168. The aft frame 168 may be coupled to the turbine inlet 254 by any now known or later developed method, such as welding or fasteners. The AFS injector 180 may be coupled to a coupler 190, as shown in FIGS. 8-12 and described above, such that the AFS injector 180 extends radially inward of the combustion chamber.

[0077] The present disclosure offers various technical and commercial advantages, examples of which are discussed herein. Additively manufactured combustor bodies lower combustor costs by eliminating the need to manufacture and then assemble a large number of parts. As a result, additive manufacturing reduces the number of components in the final combustor by as much as 70%. Additive manufacturing also enables the use of high-temperature, oxidation-resistant hot gas path (HGP) materials for the AFS immersed injectors and lower-cost materials for the combustor body. Furthermore, the AFS immersed injectors provide robust internal cooling, including near-wall and impingement cooling, while allowing for the reuse of cooling air for combustion in the combustion liner. Such robust internal cooling can be achieved through cooling structures and flow passages that are difficult to achieve with traditional manufacturing methods, such as casting and machining.

[0078] Approximate terms used throughout this specification and claims may be applied to modify any quantitative expression that can be permissibly varied without resulting in a change in the basic function to which it relates. Thus, values modified by terms such as "about," "approximately," and "substantially" are not limited to the exact value specified. In at least some instances, approximate terms may correspond to the precision of the instrument used to measure the value. Throughout this specification and claims, range limitations may be combined and / or interchanged. Such ranges are specified and include all subranges contained therein, unless the context or language indicates otherwise. "About" or "approximately," as applied to a particular value in a range, applies to both endpoints and may indicate ±10% of the stated value, unless dependent on the precision of the instrument used to measure the value.

[0079] Corresponding structure, materials, acts, and equivalents of all means or step-plus-function elements in the following claims are intended to include any structure, material, or acts for performing the function in combination with other claimed elements as specifically claimed. The description of the present disclosure has been presented for purposes of illustration and description, but is not intended to be exhaustive or limiting to the disclosure in the form disclosed. Many modifications and variations will be apparent to those skilled in the art without departing from the scope and spirit of the present disclosure. The embodiments were chosen and described to best explain the principles of the disclosure and practical application of the techniques, and to enable those skilled in the art to understand the disclosure and to contemplate various modifications to the embodiments that may be suited to the particular uses contemplated. [Explanation of symbols]

[0080] 100: Combustor 102: GT system 110: Inlet section 112: Working fluid 114: Compressor section 116: Compressed air 118: Fuel 120: Fuel supply 130: Compressor discharge casing / turbine casing / outer casing 132: Compressor discharge 134: Compressed air supply 140: Hot combustion gases 142: Turbine 146: Shaft 148: Generator 150: Exhaust gases 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: Aft frame 170: End cover 172: Cylindrical section 174: Tapered transition section 176: Fuel nozzle 178: Cap assembly 180: Axial fuel stage submerged injector / AFS submerged injector 182: Orifice 188: Injector body 190: Outer wall 192: Hollow interior 194: Film cooling hole 196: Inner wall 198: Inner side 200: Air plenum 202: Wall 204: Impingement cooling hole / first plurality of impingement cooling holes 206: First portion 208: Shroud element 210: Fuel passage 220: Fuel nozzle 222: Trailing edge 226: Mid-wall 228: Outer surface 230, 230A-230H: Second portion 232: Air passage 234: Cooling passage / near-wall cooling passage 240: End 242: Bend 244: Second plurality of impingement cooling holes 250: Coupler 252: Sleeve 254: Turbine inlet 255: Outer portion 256: Inner surface 258: Outer surface 260: Pin 262: Opening 264: Radially outer end 270: Threaded connection 272: Tack weld 282: Radially extending passageway 284: Air flow passage 286: Fuel conduit 288: First stage 290: Stationary nozzle 294: Multiple parallel sintered metal layers of a first material 296: Multiple parallel sintered metal layers of a second material 298: Passageway 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 system344: 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 / Recoat Blade 372: Raw Material 374: Gas Mixture 376: Inert Gas 380: Pump 382: Flow Valve System 386: Filter

Claims

1. An axial fuel stage (AFS) immersion injector (180), comprising: an injector body (188) configured to be disposed in a hot gas path within a combustion liner (160), the injector body (188) comprising: an outer wall (190) defining a hollow interior (192) and having a plurality of film cooling holes (194) extending from the hollow interior (192) to an exterior of the outer wall (190); an inner wall (196) spaced from an interior side (198) of the outer wall (190) along at least a portion of the length of the outer wall (190), the inner wall (196) defining an air plenum (200) therein; a first plurality of impingement cooling holes extending through the inner wall along at least a first portion of the inner wall, the first plurality of impingement cooling holes being in fluid communication with the air plenum; a fuel passage (210) extending at least partially along the hollow interior (192) of the outer wall (190); a plurality of fuel nozzles (220) extending through at least one of the inner wall (196) and the outer wall (190) to an exterior of the outer wall (190), each fuel nozzle (220) in fluid communication with a fuel passage (210).

2. 10. The AFS immersion injector of claim 1, further comprising a coupler disposed at a first end of the injector body, the coupler configured to couple the injector body within the opening in the combustion liner.

3. The AFS immersion injector (180) of claim 1, wherein the air plenum (200) comprises a plurality of air plenums.

4. further comprising an intermediate wall (226) extending along the inner wall (196) and at least one second portion (230) of the outer wall (190) from an inner side (198) of the outer wall (190) to an outer surface (228) of the inner wall (196); the intermediate wall (226) defines an air passage (232) between the intermediate wall (226) and an outer surface (228) of the inner wall (196), and defines a near-wall cooling passage (234) between the intermediate wall (226) and an inner side (198) of the outer wall (190); the intermediate wall (226) includes a second plurality of impingement cooling holes (244) fluidly coupling the near-wall cooling passage (234) defined by the intermediate wall (226) and the air passage (232); The AFS immersion injector of claim 1, wherein the air passage is in fluid communication with an outlet upstream of the first plurality of impingement cooling holes and the second plurality of impingement cooling holes.

5. 5. The AFS immersion injector of claim 4, wherein the intermediate wall includes a plurality of intermediate walls spaced apart along a plurality of second portions of each of the inner and outer walls.

6. The AFS immersion injector (180) of claim 1, wherein the plenum (200) is in fluid communication with a compressed air supply plenum (208) that extends along the exterior of the combustion liner (160).

7. A combustor (100) for a gas turbine system (102), comprising: a combustion liner (160); a plurality of axially fuel staged (AFS) submerged injectors (180) extending radially within the combustion liner (160); Each AFS immersion injector (180) includes an injector body (188); The injector body (188) an outer wall (190) defining a hollow interior (192) and having a plurality of film cooling holes (194) extending from the hollow interior (192) to an exterior of the outer wall (190); an inner wall (196) spaced from an interior side (198) of the outer wall (190) along at least a portion of the length of the outer wall (190), the inner wall (196) defining an air plenum (200) therein; a first plurality of impingement cooling holes extending through the inner wall along at least a first portion of the inner wall, the first plurality of impingement cooling holes being in fluid communication with the air plenum; a fuel passage (210) extending at least partially along the hollow interior (192) of the outer wall (190); a plurality of fuel nozzles (220) extending through at least one of an inner wall (196) and an outer wall (190) to an exterior of the outer wall (190), each fuel nozzle (220) in fluid communication with a fuel passage (210).

8. 8. The combustor of claim 7, further comprising a coupler disposed at a first end of the injector body, the coupler configured to couple the injector body within the opening of the combustion liner.

9. The combustor (100) of claim 7, wherein the air plenum (200) comprises a plurality of air plenums.

10. an intermediate wall (226) extending from an inner side (198) of the outer wall (190) along the inner wall (196) and at least one second portion (230) of the outer wall (190) to an outer surface (228) of the inner wall (196); the intermediate wall (226) defines an air passage (232) between the intermediate wall (226) and an outer surface (228) of the inner wall (196), and defines a near-wall cooling passage (234) between the intermediate wall (226) and an inner side (198) of the outer wall (190); the intermediate wall (226) includes a second plurality of impingement cooling holes (244) fluidly coupling the near-wall cooling passage (234) defined by the intermediate wall (226) and the air passage (232); The combustor of claim 7, wherein the air passage is in fluid communication with an outlet upstream of the first plurality of impingement cooling holes and the second plurality of impingement cooling holes.

11. 11. The combustor of claim 10, wherein the intermediate wall comprises a plurality of intermediate walls spaced apart along a plurality of second portions of each of the inner and outer walls.

12. The combustor (100) of claim 7, wherein the air plenum (200) is in fluid communication with a compressed air delivery plenum (208) that extends along the exterior of the combustion liner (160).

13. 8. The combustor of claim 7, further comprising a head-end fuel nozzle assembly coupled to a forward end of the combustion liner for supplying a combustible mixture of fuel and air to the combustion liner.

14. A gas turbine (GT) system (102), comprising: a compressor section (114); a combustion section operably coupled to the compressor section (114); a turbine (142) section operably coupled to the combustion section; Including, the combustion section includes at least one combustor (100) including a combustion liner (160) and a plurality of axially fuel staged (AFS) immersion injectors (180) extending radially into the combustion liner (160); Each AFS immersion injector (180) includes an injector body (188); The injector body (188) an outer wall (190) defining a hollow interior (192) and having a plurality of film cooling holes (194) extending from the hollow interior (192) to an exterior of the outer wall (190); an inner wall (196) spaced from an interior side of the outer wall (190) along at least a portion of the length of the outer wall (190), the inner wall (196) defining an air plenum (200) therein; a first plurality of impingement cooling holes extending through the inner wall along at least a first portion of the inner wall, the first plurality of impingement cooling holes being in fluid communication with the air plenum; a fuel passage (210) extending at least partially along the hollow interior (192) of the outer wall (190); a plurality of fuel nozzles (220) extending through at least one of the inner wall (196) and the outer wall (190) to an exterior of the outer wall (190), each fuel nozzle (220) in fluid communication with a fuel passage (210).

15. 15. The GT system of claim 14, further comprising a coupler disposed at the first end of the injector body, the coupler configured to couple the injector body within the opening of the combustion liner.

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