Turbomachinery component having self-breaking support - Patent application

Abstract

A turbomachine component is provided. The turbomachine component is formed from an additive manufacturing system. The additive manufacturing system defines an axial build direction, a radial direction, and a circumferential direction. The turbomachine component includes an outer portion. The outer portion includes a first end wall, a second end wall, and an outer band extending axially between the first and second end walls. The turbomachine component further includes an inner portion disposed within the outer portion. The inner portion includes a self-breaking inner band extending axially between the first and second end walls. The self-breaking inner band includes a plurality of teeth disposed between the first and second end walls.

Description

[Technical Field]

[0001] The present disclosure relates generally to turbomachine components having self-breaking supports, and more particularly to turbomachine components having an outer portion and an inner portion connected by a self-breaking support. [Background technology]

[0002] Turbomachines are widely used in fields such as power generation. For example, a conventional gas turbine system includes a compressor section, a combustor section, and a turbine section. The compressor section is configured to compress air as it flows through the compressor section. The air is then channeled from the compressor section to the combustor section, where it is mixed with fuel and combusted to generate a hot gas stream. The hot gas stream is provided to the turbine section, which extracts energy from the hot gas stream to power the compressor, a generator, and / or various other loads. Due to the complex shapes and internal geometries of many turbomachine components, additive manufacturing processes can be utilized to properly fabricate the components within tight design tolerances. For example, in a typical turbomachine, one or more rotor blades, shrouds, airfoils, fuel nozzles, and / or combustion components or subcomponents can be manufactured using additive manufacturing processes.

[0003] Additive manufacturing processes generally involve the deposition of one or more materials to create net or near-net-shape (NNS) objects, as opposed to subtractive manufacturing methods. While "additive manufacturing" is an industry standard term, additive manufacturing encompasses a variety of manufacturing and prototyping techniques known by various names, including freeform fabrication, 3D printing, rapid prototyping / tooling, etc. Additive manufacturing techniques can produce complex components from a wide variety of materials. Generally, freestanding objects can be fabricated from computer-aided design (CAD) models.

[0004] Laser sintering or laser melting is a notable additive manufacturing process for the rapid fabrication of functional prototypes and tools. Applications include the direct production of complex workpieces, patterns for investment casting, metal molds for injection molding and die casting, and molds and cores for sand casting. The production of prototype objects to facilitate concept testing during the design cycle is another common use of additive manufacturing processes.

[0005] Selective laser sintering, direct laser sintering, selective laser melting, and direct laser melting are common industry terms used to refer to the manufacturing of three-dimensional (3D) objects by using a laser beam to sinter or melt fine powder in successive layers to build a three-dimensional object in which the particles of the powder material are bonded together. More precisely, sintering involves fusing (agglomerating) the particles of powder at temperatures below the melting point of the powder material, while melting involves melting the particles of powder sufficiently to form a solid, homogeneous mass. Laser-based additive manufacturing can be applied to different material systems (e.g., engineering plastics and thermoplastic elastomers), but metal- and ceramic-based material systems are most commonly used for turbomachinery components.

[0006] The physical process associated with laser sintering or laser melting involves the transfer of heat to a powder material and the subsequent sintering or melting of the powder material. However, during the laser sintering / melting process, a three-dimensional object, such as one or more of the turbomachine components described above, is subjected to numerous thermal stresses due to the heat generated by the melting and / or sintering of the material. These thermal stresses have been shown to cause various deformations and / or distortions in the turbomachine component. Therefore, there is a need for improved turbomachine components and methods of additively manufacturing turbomachine components that advantageously minimize or eliminate distortions in the turbomachine component caused by the thermal stresses experienced during the additive manufacturing process.

[0007] Additionally, turbomachine components (such as fuel nozzles) are subjected to thermal stresses during use because they receive compressed air at a first temperature and fuel at a second temperature that may be several hundred degrees cooler than the first temperature. Thus, there is a need for improved turbomachine components and methods of additively manufacturing turbomachine components that advantageously manage the thermal stresses experienced by the turbomachine components during use. [Prior art documents] [Patent documents]

[0008] [Patent Document 1] US Patent Application Publication No. 2016 / 0348913 Summary of the Invention

[0009] Aspects and advantages of turbomachine components and methods according to the present disclosure will be set forth in part in the description that follows, or will be obvious from the description, or may be learned by practice of the technique.

[0010] According to one embodiment, a turbomachine component is provided. The turbomachine component is formed from an additive manufacturing system. The additive manufacturing system defines an axial build direction, a radial direction, and a circumferential direction. The turbomachine component includes an outer portion. The outer portion includes a first end wall, a second end wall, and an outer band extending axially between the first and second end walls. The turbomachine component further includes an inner portion disposed within the outer portion. The inner portion includes a self-breaking inner band extending axially between the first and second end walls. The self-breaking inner band includes a plurality of teeth disposed between the first and second end walls.

[0011] According to another embodiment, a method for manufacturing a turbomachine component using an additive manufacturing system is provided. The method includes irradiating a powder layer in a powder bed to form a fused region. The powder is disposed on a build plate. The method further includes depositing a subsequent powder layer on the powder bed by passing a recoater arm over the powder bed from a first side of the powder bed. The method further includes repeating the irradiating and depositing steps until the turbomachine component is formed on the build plate. The turbomachine component includes an external portion. The external portion includes a first end wall, a second end wall, and an outer band extending axially between the first and second end walls. The turbomachine component further includes an internal portion disposed within the external portion. The internal portion includes a self-breaking inner band extending axially between the first and second end walls. The self-breaking inner band includes a plurality of teeth disposed between the first and second end walls.

[0012] According to yet another embodiment, a bundle-tube fuel nozzle is provided. The bundle-tube fuel nozzle includes a first endwall, a second endwall, an outer band extending between the first and second endwalls, and an inner band extending between the first and second endwalls. The inner band is disposed within the outer band. A bellows wall is disposed between the inner and outer bands. The bellows wall surrounds the inner band such that a first fuel plenum is annularly defined between the inner and bellows walls. The inner band defines a second fuel plenum in fluid communication with the first fuel plenum through one or more openings defined in the inner band. A plurality of tubes extend axially within the second fuel plenum between the first and second endwalls.

[0013] According to another embodiment, a combustor is provided. The combustor includes a combustion liner defining a combustion chamber. The combustor further includes an outer casing surrounding the combustion liner such that an annulus is defined between the combustion liner and the outer casing. The outer casing defines a head-end volume in fluid communication with the annulus. The combustor further includes a bundle-tube fuel nozzle at least partially disposed within the head volume. The bundle-tube fuel nozzle includes a first endwall, a second endwall, an outer band extending between the first endwall and the second endwall, and an inner band extending between the first endwall and the second endwall. The inner band is disposed within the outer band. A bellows wall is disposed between the inner and outer bands. The bellows wall surrounds the inner band such that a first fuel plenum is annularly defined between the inner and bellows walls. The inner band defines a second fuel plenum in fluid communication with the first fuel plenum through one or more openings defined in the inner band. A plurality of tubes extend axially within the second fuel plenum between the first end wall and the second end wall.

[0014] These and other features, aspects, and advantages of the turbomachine components and methods of the present invention will become better understood with reference to the following description and appended claims. The accompanying drawings, which are incorporated in and constitute a part of this specification, illustrate embodiments of the present technology and, together with the description, serve to explain the principles of the technology.

[0015] A full and enabling disclosure of the turbomachine components and methods of the present invention, including the best mode of making and using the systems and methods of the present invention, directed to one of ordinary skill in the art, is set forth in this specification, with reference to the accompanying drawings. [Brief explanation of the drawings]

[0016] [Figure 1] 1 is a schematic diagram of a turbomachine according to an embodiment of the present disclosure; [Figure 2] 1 is a cross-sectional view of a combustor according to an embodiment of the present disclosure. [Figure 3]FIG. 1 is a schematic diagram of an additive manufacturing system according to an embodiment of the present disclosure. [Figure 4] 1 is a cross-sectional view of a turbomachine component in a connected position according to an embodiment of the present disclosure; [Figure 5] FIG. 5 is an enlarged view of the circled detail of FIG. 4 with the self-rupturing inner band in a connected position, according to an embodiment of the present disclosure. [Figure 6] 1 is a cross-sectional view of a turbomachine component in a disconnected position according to an embodiment of the present disclosure. [Figure 7] FIG. 7 is an enlarged view of the circled detail of FIG. 6, with the self-breaking inner band in the cut position. [Figure 8] FIG. 10 is an enlarged cross-sectional perspective view of a self-breaking inner band according to an embodiment of the present disclosure. [Figure 9] FIG. 10 is an enlarged cross-sectional perspective view of a self-breaking inner band according to an embodiment of the present disclosure. [Figure 10] FIG. 10 is an enlarged perspective view of a perforated portion extending from a first solid portion but separated from a second solid portion according to an embodiment of the present embodiment. [Figure 11] 1 is an enlarged view of a portion of the self-breaking inner band at the circumferential surface of the shaft. [Figure 12] FIG. 4 is an enlarged view of a portion of the self-breaking inner band in the axial-radial plane. [Figure 13] 1 is a flow diagram of an embodiment of a method for manufacturing a turbomachinery component using an additive manufacturing system according to embodiments of the present disclosure. [Figure 14] FIG. 2 is a cross-sectional view of a portion of a bundle-tube fuel nozzle according to an embodiment of the present disclosure. [Figure 15] FIG. 15 is a cross-sectional view of a bundle-tube fuel nozzle taken along line 15-15 shown in FIG. 6 according to an embodiment of the present disclosure. DETAILED DESCRIPTION OF THE INVENTION

[0017] Reference will now be made in detail to embodiments of the present turbomachine components and methods, one or more examples of which are illustrated in the drawings. Each example is provided by way of explanation of the present technology, not as a limitation thereof. Indeed, it will be apparent to those skilled in the art that modifications and variations can be made in the present technology without departing from the scope or spirit of the claimed technology. For example, features illustrated or described as part of one embodiment can be used in another embodiment to yield still a further embodiment. Accordingly, the present disclosure is intended to cover such modifications and variations as come within the scope of the appended claims and their equivalents.

[0018] The word "exemplary" is used herein to mean "serving as an example, instance, or illustration." Any embodiment described herein as "exemplary" is not necessarily to be construed as preferred or advantageous over other embodiments. Additionally, unless otherwise specified, all embodiments described herein should be considered exemplary.

[0019] The detailed description uses numerical and letter designations to refer to features in the drawings. Like or similar designations in the drawings and description are used to refer to like or similar parts of the invention. As used herein, the terms "first," "second," and "third" may be used interchangeably to distinguish one component from another and are not intended to denote the location or importance of individual components.

[0020] The term "fluid" can be a gas or a liquid. The term "fluid communication" means that a fluid is capable of making a connection between designated areas.

[0021] As used herein, the terms "upstream" (or "forward") and "downstream" (or "aft") refer to relative directions with respect to fluid flow in a fluid pathway. For example, "upstream" refers to the direction from which fluid flows, and "downstream" refers to the direction from which fluid flows. The term "radially" refers to relative directions that are substantially perpendicular to the axial centerline of a particular component, the term "axially" refers to relative directions that are substantially parallel to and / or coaxially aligned with the axial centerline of a particular component, and the term "circumferentially" refers to relative directions that extend around the axial centerline of a particular component.

[0022] Approximate terms such as "approximately," "about," "generally," and "substantially" are not intended to be limited to the exact value stated. In at least some cases, approximating language can correspond to the precision of an instrument for measuring a value or the precision of a method or machine for constructing or manufacturing a component and / or system. In at least some cases, approximating language can correspond to the precision of an instrument for measuring a value or the precision of a method or machine for constructing or manufacturing a component and / or system. For example, approximating language can refer to within a margin of 1, 2, 4, 5, 10, 15, or 20% of an individual value, a range of values, and / or any of the endpoints defining the range of values. When used in the context of angles or directions, such terms include a range of plus or minus 10 degrees of the stated angle or direction. For example, "approximately vertical" includes directions within 10 degrees of any direction, e.g., clockwise or counterclockwise, from vertical.

[0023] Terms such as "coupled," "fixed," and "attached," unless otherwise stated herein, refer to both direct coupling, fixing, or attachment, and indirect coupling, fixing, or attachment via one or more intermediate components or features. As used herein, the terms "comprises," "comprising," "includes," "including," "has," and "having," or any other variation thereof, are intended to cover a non-exclusive inclusion. For example, a process, method, article, or apparatus that includes a list of features is not necessarily limited to only those features but may include other features not expressly listed or that are inherent to such process, method, article, or apparatus. Furthermore, unless expressly stated otherwise, "and / or" refers to an inclusive condition rather than an exclusive condition. For example, conditions A and / or B are satisfied by any one of the following: A is true (or exists) and B is false (or does not exist), A is false (or does not exist) and B is true (or exists), and both A and B are true (or exist).

[0024] Here and throughout the specification and claims, range limitations are combinable and interchangeable, and unless the context and language dictate otherwise, such ranges are identified and include all subranges subsumed therein. For example, all ranges disclosed herein are inclusive of the endpoints, and the endpoints are independently combinable with each other.

[0025] As described in detail below, exemplary embodiments of the present subject matter include the use of an additive manufacturing machine or method. As used herein, the terms "additively manufactured" or "additive manufacturing technique or process" generally refer to a manufacturing process in which successive layers of material are provided on top of each other to "build up" a three-dimensional component layer by layer. The successive layers generally fuse together to form a monolithic component that may have various integral subcomponents.

[0026] The additive manufacturing processes described herein can be used to form components using any suitable material. For example, the material can be a metal, ceramic, solid, liquid, powder, sheet material, wire, or any other suitable material that can be in any other suitable form. More specifically, according to exemplary embodiments of the present subject matter, the additively manufactured components described herein can be partially or completely formed from materials such as, but not limited to, pure metals, nickel alloys, chromium alloys, titanium, titanium alloys, magnesium, magnesium alloys, aluminum, aluminum alloys, iron, iron alloys, stainless steel, and nickel- or cobalt-based superalloys (e.g., superalloys available from Special Metals Corporation under the name Inconel®), or can be formed from any combination of these materials. These materials are examples of materials suitable for use in the additive manufacturing processes described herein and may be generally referred to as “additive materials.”

[0027] References to "fusing" as used herein can refer to any suitable process for creating a bonded layer of any of the above materials. For example, if the material is a ceramic, the bond may be formed by a sintering process. If the material is a powdered metal, the bond can be formed by a melting or sintering process. Those skilled in the art will appreciate that other methods of fusing materials to create components by additive manufacturing are possible and the presently disclosed subject matter can be practiced with those methods.

[0028] Each successive layer may be, for example, about 10 μm (micrometers) to 200 μm (micrometers), although the thickness may be selected based on any number of parameters and may be any suitable size according to alternative embodiments. Thus, utilizing the additive manufacturing methods described above, the components described herein may have a cross-section as thin as the thickness of one of the associated powder layers utilized in the additive manufacturing process, such as, for example, 10 μm.

[0029] In particular, in exemplary embodiments, some features of the components described herein were previously not possible due to manufacturing constraints. However, the inventors have advantageously utilized current advances in additive manufacturing technology to develop exemplary embodiments of such components in accordance with the present disclosure. While the present disclosure is not limited to the use of additive manufacturing to generally form these components, additive manufacturing offers various manufacturing advantages, such as ease of production, reduced cost, and increased precision.

[0030] Referring now to the drawings, Figure 1 shows a schematic diagram of one embodiment of a turbomachine, which in the illustrated embodiment is a gas turbine 10. Although an industrial or land-based gas turbine is shown and described herein, the present disclosure is not limited to industrial and / or land-based gas turbines unless otherwise stated in the claims. For example, the turbomachine components described herein may be used in any type of turbomachine, including, but not limited to, a steam turbine, an aircraft gas turbine, or a marine gas turbine.

[0031] As shown, the gas turbine 10 generally includes an inlet section 12, a compressor section 14 disposed downstream from the inlet section 12, a plurality of combustors 17 (one of which is shown) in a combustor section 16 disposed downstream from the compressor section 14, a turbine section 18 disposed downstream from the combustor section 16, and an exhaust section 20 disposed downstream from the turbine section 18. Additionally, the gas turbine 10 may include one or more shafts 22 coupled between the compressor section 14 and the turbine section 18.

[0032] Compressor section 14 may generally include a plurality of rotor disks 24 (one of which is shown) and a plurality of rotor blades 26 connected to and extending radially outward from each rotor disk 24. In turn, each rotor disk 24 may be coupled to or form a portion of a shaft 22 that extends through compressor section 14.

[0033] Turbine section 18 may generally include a plurality of rotor disks 28 (one of which is shown) and a plurality of rotor blades 30 extending radially outward from and interconnected to each rotor disk 28. Each rotor disk 28 may in turn be coupled to or form a portion of a shaft 22 that extends through turbine section 18. Turbine section 18 further includes an outer casing 33 circumferentially surrounding the portion of shaft 22 and rotor blades 30, thereby at least partially defining a hot gas path 32 through turbine section 18.

[0034] During operation, a working fluid, such as air, flows through the inlet section 12 into the compressor section 14, where the air is progressively compressed through stages of rotating blades 26 and stationary nozzles (not shown), thus providing pressurized or compressed air 25 to the combustors 17 of the combustor section 16. The compressed air 25 is mixed with fuel and combusted in each combustor 17 to generate combustion gases. The combustion gases 34 flow from the combustor section 16 through the hot gas path 32 into the turbine section 18, where energy (kinetic and / or thermal energy) is transferred from the combustion gases 34 to the rotor blades 30, thereby rotating the shaft 22. This mechanical, rotational energy can then be used to power the compressor section 14 and / or generate electricity. The spent combustion gases 34 exiting the turbine section 18 can then be exhausted from the gas turbine 10 via the exhaust section 20.

[0035] As shown in FIG. 2 , the combustor 17 may be at least partially enclosed by a compressor discharge casing 36. The compressor discharge casing 36 may at least partially define a high-pressure plenum 38 that at least partially surrounds various components of the combustor 17. The high-pressure plenum 38 may be in fluid communication with the compressor section 14 ( FIG. 1 ) and may receive the compressed air 25 therefrom. An end cover 35 may be coupled to the outer casing 33. In certain embodiments, the outer casing 33 and the end cover 35 may at least partially define a head-end volume or portion 37 of the combustor 17.

[0036] In certain embodiments, the combustion liner 40 may at least partially define a combustion chamber or zone 42 for combusting the fuel-air mixture and / or may at least partially define a hot gas path through the combustor 17 for directing the combustion gases 34 toward an inlet of the turbine section 18. The head end portion 37 may be in fluid communication with the high-pressure plenum 38 and / or the compressor section 14 via a cooling flow annulus 41 defined between the combustion liner 40 and the outer casing 33.

[0037] In various embodiments, the combustor 17 includes at least one bundle-tube fuel nozzle 200. In one embodiment, the bundle-tube fuel nozzle 200 forms the head-end portion 37 of the combustor 17. As shown in FIG. 2 , the bundle-tube fuel nozzle 200 is positioned within the outer casing 33 upstream of the combustion chamber 42 and downstream of and / or axially spaced from the end cover 35 relative to an axial centerline 46 of the combustor 17. In certain embodiments, the bundle-tube fuel nozzle 200 is in fluid communication with a gas fuel supply 48 via one or more fluid conduits 50. In certain embodiments, the fluid conduits 50 may be fluidly coupled and / or connected at one end to the end cover 35.

[0038] To illustrate one example of an additive manufacturing system and process, Figure 3 shows a schematic / block diagram of an additive manufacturing system 100 for producing an object 122, which may be a bundle-tube fuel nozzle 200. The additive manufacturing system 100 may be configured for direct metal laser sintering (DMLS) or direct metal laser melting (DMLM). For example, the additive manufacturing system 100 may produce objects such as the bundle-tube fuel nozzle 200 or other components.

[0039] For example, object 122 can be fabricated layer by layer by sintering or melting powder material in powder bed 112 using an energy beam 136 generated by a light source such as laser 120. The powder melted by the energy beam is supplied by reservoir 126 and uniformly distributed onto build plate 102 using a recoater arm 116 moving in a recoater direction 134, maintaining the powder at level 118 and removing excess powder material extending above powder level 118 to a waste container 128. The energy beam 136 sinters or melts a cross-sectional layer of the object being built under the control of a galvo scanner 132. Build plate 102 is lowered, and another layer of powder is distributed onto the build plate and object being built, followed by subsequent powder melting / sintering by laser 120. The process is repeated until object 122 is fully built from the fused / sintered powder material.

[0040] The laser 120 can be controlled by a computer system including a processor and memory. The computer system can determine a scan pattern for each layer and control the laser 120 to irradiate the powder material according to the scan pattern. After fabrication of the object 122 is complete, various post-processing procedures can be applied to the object 122. Post-processing procedures include, for example, removing excess powder by blowing or suction. Advantageously, in the case of the present bundle-tube fuel nozzle 200 (for reasons described herein), other post-processing procedures include stress relief processes. Additionally, thermal and chemical post-processing procedures can be used to finish the object 122.

[0041] In the exemplary embodiment, the additive manufacturing system 100 is configured to operate in an axial build direction A AM (or build direction), radial direction R perpendicular to the build direction AM , and a circumferential direction C extending around the build direction AM A cylindrical coordinate system can be defined having:

[0042] 4-7 , various views of a turbomachine component 300 are shown in accordance with an embodiment of the present disclosure. For example, FIG. 4 shows a cross-sectional view of the turbomachine component 300 in a connected position, FIG. 5 shows an enlarged view of the circled detail in FIG. 4 , illustrating the inner band or self-breaking inner band 312 in a connected position, FIG. 6 shows a cross-sectional view of the turbomachine component 300 in a disconnected position, and FIG. 7 shows an enlarged view of the circled detail in FIG. 6 , illustrating the self-breaking inner band 312 in a disconnected position. In an exemplary embodiment, the turbomachine component 300 may be the bundle-tube fuel nozzle 200 described above with reference to FIGS. 2 and 3 . However, in other embodiments, the turbomachine component may be any other component of the gas turbine 10, such as a turbine / compressor rotor blade, a stator vane, a turbine nozzle, or one of the other gas turbine components, and the turbomachine component 300 should not be limited to any particular component of the turbomachine unless specifically recited in the claims.

[0043] In an exemplary embodiment, turbomachinery component 300 may be formed from an additive manufacturing system (e.g., additive manufacturing system 100 described above with reference to FIG. 2). Turbomachinery component 300 may define a cylindrical coordinate system that is fully aligned with the cylindrical coordinate system of additive manufacturing system 100. For example, as shown in FIG. 4, turbomachinery component 300 extends along an axial centerline 301 of turbomachinery component 300 (axial build direction A AM Axial direction A (parallel to TC , axial direction A TC The radial direction R extends perpendicular to TC , and the axial direction A TC Circumferential direction C extending around TCcan be defined.

[0044] The turbomachine component 300 may include an external portion 302 and an internal portion 304 within and connected to the external portion 302. For example, the internal portion 304 may extend completely within the external portion 302 or may be coupled to the external portion 302 at one or more locations. In many embodiments, the external portion 302 and the internal portion 304 of the turbomachine component 300 may be concentric structures, where the external portion 302 and the internal portion 304 define the same shape but have different sizes. Furthermore, the internal portion 304 and the external portion 302 may share a common axial centerline (e.g., the internal portion 304 and the external portion 302 may be coaxial). For example, the axial centerline 301 of the turbomachine component 300 may be common to both the internal portion 304 and the external portion 302.

[0045] In various embodiments, the inner portion 304 and the outer portion 302 may be annular. For example, the inner portion 304 and the outer portion 302 may each extend annularly around the axial centerline 301 of the turbomachine component 300. Furthermore, the inner portion 304 and the outer portion 302 may be coaxially aligned with each other and with the axial centerline 301 of the turbomachine component 300. In many embodiments, the outer portion 302 and the inner portion 304 may be concentric with each other such that the outer portion 302 and the inner portion 304 share a common center point (and / or axial centerline).

[0046] In many embodiments, the outer portion 302 may include a first or front end wall 306, a second or rear end wall 308, and an outer band 310 extending axially between the first end wall 306 and the second end wall 308. The first end wall 306 and the second end wall 308 may be generally parallel to one another and may extend generally radially. The outer band 310 may extend annularly axially around the axial centerline 301 (e.g., 360° circumferentially) and between the first end wall 306 and the second end wall 308.

[0047] In the exemplary embodiment, inner portion 304 may be disposed within outer portion 302. Inner portion 304 may include a self-breaking inner band 312 extending axially between first end wall 306 and second end wall 308. Self-breaking inner band 312 may extend annularly about axial centerline 301 of turbomachine component 300. Self-breaking inner band 312 may be radially spaced from outer band 310 such that an annular plenum 315 is defined therebetween.

[0048] In the exemplary embodiment, the self-breaking inner band 312 may include a first solid portion 318, a second solid portion 320, and a perforated portion 322 disposed (e.g., axially) between the first solid portion 318 and the second solid portion 320. The first solid portion 318 may extend from the first end wall 306 to the perforated portion 322, and the second solid portion 320 may extend from the second end wall 308 to the perforated portion 322. The perforated portion 322 may include one or more through holes, perforations, voids, or gaps extending through the self-breaking inner band 312 to facilitate separating the self-breaking inner band 312 into two separate portions. As used herein, the term “solid,” when used with reference to a component or portion of a component, may refer to an impermeable component such that the component does not allow air or other fluids to pass through. For example, the first solid portion 318 and the second solid portion 320 of the self-rupturing inner band 312 may each be impermeable and free of through holes or other gaps. In various embodiments, the first solid portion 318 may be axially longer than the second solid portion 320.

[0049] In various embodiments, such as those in which the turbomachine component 300 is a bundle-tube fuel nozzle 200, the bellows wall 316 may extend between the first end wall 306 and the self-breaking inner band 312. In particular, the bellows wall 316 may extend between the first end wall 306 and the second solid portion 320 of the self-breaking inner band 312. The bellows wall 316 may extend in the axial A direction to allow for axial thermal growth between the inner portion 304 and the outer portion 302. TC For example, if self-breaking inner band 312 breaks or severs, bellows wall 316 may thermally expand / contract in the axial direction during operation of turbomachinery component 300. First fuel plenum 317 may be defined between bellows wall 316 and self-breaking inner band 312.

[0050] In some embodiments, the self-breaking inner band 312 may define a second fuel plenum 324 in fluid communication with the first fuel plenum 317 such that the second fuel plenum 324 receives fuel from the first fuel plenum 317. In some embodiments, the first fuel plenum 317 may be in fluid communication with the second fuel plenum 324 through one or more openings 326 (shown in dashed lines). In such embodiments, the self-breaking inner band 312 may include three solid portions instead of two, e.g., a first solid portion extending axially from the first end wall 306 to the one or more openings 326, a second solid portion extending axially from the one or more openings 326 to the perforated portion 322, and a third solid portion extending from the perforated portion 322 to the second end wall 308.

[0051] In many embodiments, the bundle-tube fuel nozzle 200 may further include a plurality of tubes 328, each defining a premix passage 334 and extending from an inlet 330 defined in the first endwall 306 through the second fuel plenum 324 to an outlet 332 defined in the second endwall 308. Additionally, a fuel port or hole 331 may be defined in each tube 328 of the plurality of tubes 328 to provide fluid communication between the second fuel plenum 324 and the premix passage 334. During operation, each premix passage 334 may receive air at the inlet 330 and fuel at the fuel port 331, which mix with each other and are discharged at the outlet 332 for combustion. While FIGS. 4 and 6 show the bundle-tube fuel nozzle 200 having two tubes 328 for purposes of illustration, it should be understood that the bundle-tube fuel nozzle 200 may include any number of tubes 328, and the present invention should not be limited to any particular number of tubes 328 unless specifically recited in the claims. For example, the central broken line in FIGS. 4 and 6 is used to indicate that the bundle-tube fuel nozzle 200 may include any number of tubes 328 .

[0052] In the exemplary embodiment, the self-breaking inner band 312 may include a plurality of teeth 350 disposed between the first end wall 306 and the second end wall 308. In particular, the perforated portion 322 may extend circumferentially about the axial centerline 301 and may include a plurality of teeth 350 disposed in a common axial plane between the first end wall 306 and the second end wall 308. The plurality of teeth 350 may be sized and shaped to break in response to thermal stress or other forces. In many implementations, the plurality of teeth 350 may be separable from the second solid portion 320 in response to a break force such that the self-breaking inner band 312 is transitionable from a connected state (shown in FIGS. 4 and 5 ) to a disconnected state (shown in FIGS. 6 and 7 ). In other words, the turbomachine component 300 may be formed by additive manufacturing with the self-breaking inner band 312 in an unbroken position (shown in FIGS. 4 and 5 ). Subsequently, the turbomachine component may be subjected to a breaking force, thermal cycle, or operating cycle that physically separates the first solid portion 318 of the self-breaking inner band 312 extending from the first endwall 306 from the second solid portion 320 extending from the second endwall 308 (as shown in FIGS. 6 and 7 ). For example, as a result of the breaking force, thermal cycle, or operating cycle, the self-breaking inner band 312 may be divided from a single wall extending continuously from the first endwall 306 to the second endwall 308 into the first solid portion 318 and the second solid portion 320 via a gap 344. The gap 344 may be defined between the first solid portion 318 and the second solid portion 320 after the self-breaking inner band 312 breaks at the perforated portion 322.

[0053] 8 and 9, there are shown two different enlarged perspective views of the self-breaking inner band 312 according to an embodiment of the present disclosure. For example, FIGS. 8 and 9 each show an enlarged cross-sectional perspective view of the self-breaking inner band 312.

[0054] 8 and 9 , perforated portion 322 may include a plurality of walls 346 that are spaced apart (e.g., circumferentially spaced apart) from one another such that a circumferential perforation 348 is defined between each adjacent pair of walls 346 of the plurality of walls 346. Further, in an exemplary embodiment, a plurality of teeth 350 may extend from each wall 346 of the plurality of walls 346. Each wall 346 of the plurality of walls 346 may extend between first solid portion 318 and a plurality of teeth 350 disposed at an end of each wall 346 of the plurality of walls 346. A plurality of teeth 350 disposed at an end of each wall 346 may extend between the respective wall 346 and second solid portion 320.

[0055] 10 , a perspective view of a portion of the self-breaking inner band 312 is shown in accordance with an embodiment of the present disclosure. In particular, FIG. 10 shows an enlarged perspective view of the perforated portion 322 extending from the first solid portion 318 but separated from the second solid portion 320 to illustrate the configuration of the walls 346 and the teeth 350. In many embodiments, each tooth 350 may be generally wedge-shaped and may extend between a respective wall 346 of the walls 346 and the second solid portion 320. However, in other embodiments (not shown), each tooth 350 may have other shapes, such as a cylindrical shape, a conical shape, etc.

[0056] As shown in FIG. 10 , at least one tooth 350 of the plurality of teeth 350 may taper in thickness as the at least one tooth 350 extends axially from a respective wall 346 of the plurality of walls 346. For example, as shown in FIG. 10 , each tooth of the plurality of teeth 350 may taper in thickness as the tooth extends from a respective wall 346 of the plurality of walls 346. In particular, in an exemplary embodiment, each wall 346 and each tooth 350 may define a constant, common circumferential thickness 352. For example, the common circumferential thickness 352 may be shared (or common) by each respective wall 346 and each tooth 350 extending from each respective wall 346. The common circumferential thickness 352 may be varied in the axial direction A so that the circumferential thickness of the wall 346 and the plurality of teeth 350 does not change as the wall 346 and the plurality of teeth 350 extend axially. TCmay be constant at

[0057] In various embodiments, as shown in FIG. 10 , each tooth 350 may extend from a base 360 ​​coupled to the wall 346 to a tip 362 coupled to the second solid portion 320. Further, each tooth 350 may taper from a first radial thickness 354 at the base 360 ​​to a second radial thickness 356 at the tip 362. In other words, the tooth 350 may continuously taper in the radial direction (e.g., a linear taper) as each tooth 350 extends axially from the base 360 ​​to the tip 362. Notably, as shown in FIG. 10 , each tooth 350 of the plurality of teeth 350 may define a fracture surface 358 at the tip 362. The fracture surface 358 may be defined at an intersection between the tip 362 of the tooth 350 and the second solid portion 320 of the self-breaking inner band 312.

[0058] In many embodiments, fracture surface 358 can include a common circumferential thickness 352 and a second radial thickness 356. In such embodiments, common circumferential thickness 352 may be between about 100% and about 500% of second radial thickness 356 at fracture surface 358, or, for example, between about 150% and about 450%, or, for example, between about 200% and about 400%. This is advantageous over tooth(s) having, for example, a large first dimension and a small second dimension (i.e., a thin fracture support) because it prevents debris from falling into plenums 317 and / or 324 and becoming trapped within turbomachinery component 300. For example, an embodiment in which one of the circumferential thickness or second radial thickness is greater than about 600% of the other is disadvantageous because it results in a tooth that is too thin in one direction, thereby causing undesirable debris within turbomachinery component 300 when the tooth fractures.

[0059] 11 , an enlarged view of a portion of the self-breaking inner band 312 in an axial circumferential plane is shown in accordance with an embodiment of the present disclosure. As shown, each wall 346 may extend axially from a root 370 connected to the first solid portion 318 to a base 360 ​​(shown in phantom) of a plurality of teeth 350, and each tooth 350 may extend axially between the base 360 ​​connected to the respective wall 346 and a tip 362 connected to the second solid portion 320. As shown in FIG. 11 , each circumferential perforation 348 may be collectively defined by two adjacent walls 346, the first solid portion 318, and the second solid portion 320. The first solid portion 318 may include a rounded boundary surface 364 (or an arcuate boundary surface) that partially defines a forward end of the circumferential perforation 348. The rounded boundary surface may be semicircular. Additionally, the second solid portion 320 may include a flat boundary surface 366 that partially defines the aft ends of the circumferential perforations 348 .

[0060] 12 , an enlarged view of a portion of the self-breaking inner band 312 in an axial-radial plane is shown in accordance with an embodiment of the present disclosure. As shown, the wall 346 may extend axially from a root 370 (shown in phantom) connected to the first solid portion 318 to a base 360 ​​(shown in phantom) of a plurality of teeth 350, with each tooth 350 extending axially between the base 360 ​​connected to the wall 346 and a tip 362 (shown in phantom) connected to the second solid portion 320. As shown in FIG. 12 , each tooth 350 may include a straight surface 372 and an inclined surface 374. The straight surface 372 is angled in the axial A direction of the turbomachine component 300. TC The angled surface 374 may extend substantially parallel to the straight surface 372. The angled surface 374 may continuously converge toward the straight surface 372 as the tooth 350 extends axially between the base 360 ​​and the tip 362.

[0061] While FIG. 12 illustrates the inclined surface 374 of each tooth 350 as defined in the axial-radial plane, it should be understood that each tooth 350 may additionally or alternatively include an inclined surface in the axial-circumferential plane (or other planes). Also, while FIGS. 4-10 and 12 illustrate the plurality of teeth 350 as having a trapezoidal shape in the axial-radial plane, the teeth of the present invention should not be limited to any particular shape unless specifically recited in the claims. Each tooth 350 of the plurality of teeth 350 may converge in cross-sectional area as each tooth 350 extends axially from the base 360 ​​to the tip 362, and thus each tooth 350 may define a number of cross-sectional shapes not necessarily limited to those shown in FIGS. 4-10 and 12.

[0062] However, in an exemplary embodiment, each of the plurality of teeth 350 can define a trapezoidal cross-sectional shape in the axial-radial plane (or the axial-circumferential plane, or both the axial-radial and axial-circumferential planes). In such an embodiment, shown in FIG. 12 , each tooth 350 can include an inclined surface 374 and a straight surface 372, which can be advantageous over other designs because it facilitates additive manufacturing of a defect-free, self-breaking inner wall and promotes fracture at the location of the tooth 350 during operation of the component 300.

[0063] In an exemplary embodiment, as shown in FIG. 12 , a radial perforation 376 may be defined between each pair of adjacent teeth 350 of the plurality of teeth 350. For example, each radial perforation 376 may be collectively defined by two adjacent teeth 350 of the plurality of teeth 350 and the second solid portion 320. For example, each radial perforation 376 may be collectively defined by the straight surface 372 of a first tooth of the plurality of teeth 350, the inclined surface of a second tooth of the plurality of teeth 350 adjacent (e.g., directly adjacent) to the first tooth, and the second solid portion 320. The radial perforations 376 may be generally formed as a triangle (e.g., a right-angled triangle). In this manner, the radial perforations 376 may be aligned in the axial direction A. TC The radial thickness may be defined to increase gradually.

[0064] In many embodiments, both the outer band 310 and the self-breaking inner band 312 are each thin-walled cylinders. For example, as described above, the outer band 310 and the self-breaking inner band 312 may be annular components such that the outer band 310 and the self-breaking inner band 312 define thin-walled cylinders that are concentric with one another. In some embodiments, each thin-walled cylinder can have a wall thickness that is less than about 15% (or less than about 10%, or less than about 5%) of the diameter of the thin-walled cylinder.

[0065] Referring now to FIG. 13 , a flow diagram of one embodiment of a method 1300 for manufacturing a turbomachinery component 300 using an additive manufacturing system 100 in accordance with aspects of the present subject matter is shown. Generally, the method 1300 is described herein with reference to the gas turbine 10, turbomachinery component 300, and additive manufacturing system 100 described above with reference to FIGS. 1-12 . However, those skilled in the art will understand that the disclosed method 1300 may generally be utilized with any suitable gas turbine and / or in connection with any additive manufacturing system having any other suitable system configuration. Furthermore, while FIG. 13 depicts steps performed in a particular order for purposes of illustration and explanation, the methods described herein are not limited to any particular order or arrangement unless otherwise specified in the claims. Those skilled in the art, using the disclosure provided herein, will understand that various steps of the methods disclosed herein may be omitted, rearranged, combined, and / or adapted in various ways without departing from the scope of the present disclosure.

[0066] In many embodiments, the method 1300 can include irradiating (at step 1302) a powder layer in the powder bed 112 to form a fused region. In many embodiments, the powder bed 112 can be disposed on the build plate 102 such that the fused region is fixedly attached to the build plate 102, as shown in FIG. 3 . The method 1300 can further include (at step 1304) providing a subsequent powder layer on the powder bed 112 (e.g., from a first side of the powder bed 112) by passing a recoater arm 116 over the powder bed 112. The recoater arm 116 can distribute each powder layer on the powder bed 112 by passing over the powder bed 112 from the first side to the second side while depositing (e.g., dispensing) powder on the powder bed 112. The method 1300 further includes repeating steps 1302 and 1304 (step 1306) until the turbomachine component 300 is formed in the powder bed 112. The additively manufactured turbomachine component 300 is then removed from the build plate 102.

[0067] In an optional embodiment, the method 1300 may further include subjecting the turbomachine component 300 to one or more stress relief processes (three examples of which are shown). In one embodiment, the method 1300 includes applying a breaking force to the turbomachine component 300 (step 1308). The breaking force may be mechanically (or manually) applied to the outer portion 302 of the turbomachine component 300. As a result, as shown in the method 1300 (step 1314), the self-breaking inner band 312 may split into a first portion extending from the first end wall and a second portion extending from the second end wall. Once the self-breaking inner band 312 is split, a gap 344 may be defined between the first and second portions (as shown in FIGS. 6 and 7 ).

[0068] Additionally or alternatively, method 1300 may further include subjecting turbomachine component 300 to a thermal cycle (step 1310) in which a first temperature of one of external portion 302 or internal portion 304 is elevated relative to a second temperature of the other of external portion 302 or internal portion 304. Elevating the first temperature of one of external portion 302 or internal portion 304 relative to the second temperature of the other of external portion 302 or internal portion 304 may advantageously induce thermal stresses in perforated portion 322 that separates plurality of teeth 350 from second solid portion 320 of self-breaking inner band 312. As a result, as shown in method 1300 (step 1314), self-breaking inner band 312 may be divided into a first portion extending from the first end wall and a second portion extending from the second end wall. When the self-breaking inner band 312 is split, a gap 344 may be defined between the first and second portions (as shown in FIGS. 6 and 7).

[0069] In some embodiments, the method 1300 may further include subjecting the turbomachinery component 300 to an operating cycle within the gas turbine 10 (step 1312). For example, the turbomachinery component 300 may be a bundle-tube fuel nozzle 200, and the operating cycle may include operating the gas turbine 10 by rotating a compressor section to generate compressed air, igniting the bundle-tube fuel nozzle 200 in a combustion section to generate combustion gases, and expanding the combustion gases to rotate a turbine section. As a result, as shown in the method 1300 (step 1314), the self-breaking inner band 312 may be split into a first portion extending from the first endwall and a second portion extending from the second endwall. Once the self-breaking inner band 312 is split, a gap 344 may be defined between the first and second portions (as shown in FIGS. 6 and 7 ).

[0070] The self-breaking inner band 312 can advantageously facilitate additive manufacturing of the turbomachinery component 300 without distortion or manufacturing failure because the self-breaking inner band 312 remains connected during and immediately after manufacturing of the turbomachinery component 300. Subsequently, after being subjected to a breaking force, thermal cycle, or operating cycle, the self-breaking inner band 312 can be split into two separate, unconnected portions, allowing the turbomachinery component 300 to thermally expand during operation without cracking or fracturing. For example, once the self-breaking inner band 312 is cut or otherwise separated, the inner portion 304 can thermally expand relative to the outer portion 302 without causing excessive thermal stresses to the turbomachinery component 300. This thermal expansion may be further aided by the corrugated bellows wall 316 to expand / contract in response to the thermal expansion of the turbomachinery component. Furthermore, the inner portion 304 may be completely contained within the outer portion 302 of the turbomachinery component 300 such that it is not accessible from the outside. Thus, the self-breaking inner band 312 can break without direct contact, such as in response to a breaking force applied externally to the turbomachinery component 300 or in response to thermal / operational cycling of the turbomachinery component 300.

[0071] 14 and 15 , two different cross-sectional views of a bundle-tube fuel nozzle 200 according to an embodiment of the present disclosure are shown. For example, FIG. 14 shows an enlarged cross-sectional view of a portion of the bundle-tube fuel nozzle 200, and FIG. 15 shows a cross-sectional view of the bundle-tube fuel nozzle 200 taken along line 15-15 shown in FIG. 6 . As shown, the bundle-tube fuel nozzle 200 includes a first endwall 306 and a second endwall 308. An outer band 310 may extend between the first endwall 306 and the second endwall 308, and an inner band 312 may extend between the first endwall 306 and the second endwall 308. Both the outer band 310 and the inner band 312 may extend annularly around an axial centerline 301 of the bundle-tube fuel nozzle 200. The inner band 312 may be disposed within the outer band 310.

[0072] In the exemplary embodiment, bundle-tube fuel nozzle 200 may further include a bellows wall 316 disposed between inner band 312 and outer band 310. The bellows wall may surround inner band 312 such that a first fuel plenum 317 is annularly defined between inner band 312 and bellows wall 316. Further, inner band 312 may define a second fuel plenum 324 in fluid communication with first fuel plenum 317 via one or more openings 326 defined in inner band 312.

[0073] The bellows wall 316 may be corrugated to thermally expand and contract during operation of the bundle-tube fuel nozzle 200. The bellows wall 316 may provide increased structural and thermal integrity to the bundle-tube fuel nozzle 200, thereby increasing hardware life and reducing the likelihood of failure due to thermal stresses.

[0074] In many embodiments, the bellows wall 316 may extend between the first end wall 306 and the inner band 312. In other embodiments (not shown), the bellows wall 316 may extend between the outer band 310 and the inner band 312. As described in detail above, the inner band 312 may include a perforated portion 322. In such embodiments, the bellows wall 316 may extend (relative to the flow of air / fuel through the tube 328) from the first end wall 306 to the inner band 312 downstream of the perforated portion 322. Or, in other words, the bellows wall 316 extends from the first end wall 306 to the inner band 312 in the axial direction A. TC 322 axially aft (downstream) of the perforated portion 322 .

[0075] As shown in FIG. 14 , the bellows wall 316 may have a plurality of angled portions 380 and a plurality of arcuate apices 382, ​​each disposed between two of the plurality of angled portions 380. The arcuate apices 382 may form an intersection or junction between two of the plurality of angled portions 380. The arcuate apices 382 may be generally rounded, contoured, curved, or rounded (e.g., without abrupt or sudden changes in direction), which advantageously facilitates additive manufacturing of the bundle-tube fuel nozzle 200. For example, in an exemplary embodiment, the bundle-tube fuel nozzle 200 may be additively manufactured using the additive manufacturing system 100 described above with reference to FIG. 3 . In such an embodiment, the bundle-tube fuel nozzle 200 may be additively manufactured using the additive manufacturing system 100 described above with reference to FIG. 3 . In such an embodiment, the bundle-tube fuel nozzle 200 may be additively manufactured using the additive manufacturing system 100 in a build direction A. AM is the axial direction A of the bundle-tube fuel nozzle 200 TC Alternatively, in other embodiments (not shown), the build direction A AM is the axial direction A of the bundle-tube fuel nozzle 200 TC may be in the same direction.

[0076] In various embodiments, the angled portion is TC and axial direction A TC For example, the angle 384 may be angled relative to each of the plurality of angled portions 380 and the axial direction A. TC (and / or axial build direction A AM ), and angle 384 may be greater than about 40°. In particular, angle 384 may be between about 40° and about 65°, or, for example, between about 40° and about 60°, or, for example, between about 40° and about 55°, or, for example, about 45°. Angle 384 can advantageously ensure that bellows wall 316 can be additively manufactured without excessive overhang that could cause defects. Furthermore, angle 384 advantageously increases thermal compliance during operation of bundle-tube fuel nozzle 200.

[0077] The plurality of angled portions 380 may include an initial angled portion 386, a plurality of intermediate angled portions 388, and a final angled portion 390. Additionally, the bellows wall 316 may include a straight portion 392 extending from the first end wall 306 to the initial angled portion 386 of the plurality of angled portions 380. In other words, the initial angled portion 386 may extend from the straight portion 392 to the arcuate apex 382. Each of the intermediate angled portions 388 may extend between two of the arcuate apexes 382. The final angled portion 390 of the plurality of angled portions may extend from the arcuate apex 382 to the inner band 312. The final angled portion 390 may be the longest angled portion of the plurality of angled portions 380 (e.g., about 10% to about 50% longer than the intermediate angled portions 388 and / or the initial angled portions 386).

[0078] 14 , the bundle-tube fuel nozzle 200 may include a delimiter 394 extending radially outward from the outer band 310. The delimiter 394 may form part of the outer band 310 and may extend annularly about the axial centerline 301 of the bundle-tube fuel nozzle 200. The delimiter 394 may be the radially outermost portion of the bundle-tube fuel nozzle 200, and the delimiter 394 may define a forward face 396 and an aft face 398.

[0079] In many embodiments, the bundle-tube fuel nozzle 200 may include an annular air plenum 400 defined between the outer band 310 and the bellows wall 316. In particular, the annular air plenum 400 may be collectively defined by the outer band 310, the bellows wall 316, the second end plate 308, and a portion of the inner band 312. An inlet 402 to the annular air plenum 400 may be defined via the delimiter 394. The inlet 402 extends in a radial direction R. TC and axial direction A TCThe inlets 402 may extend through the front face 396 of the delimiter 394. Additionally, outlets 404 to the annular air plenum 400 may be defined through the second end wall 308. The inlets 402 may be fluidly coupled to an air source 406 (which may be the head end volume 37 or another air source). The outlets 404 may supply film cooling air to the second end plate 308 during operation of the bundle-tube fuel nozzle 200. One or more inlets 402 and one or more outlets 404 may be used.

[0080] In certain embodiments, a conduit 410 extends from the first end plate 306 and defines a fuel inlet 412. The fuel inlet 412 may be fluidly coupled to a fuel source 414 (e.g., a hydrogen fuel source, a natural gas fuel source, or other fuel source) and a first fuel plenum 317. The conduit 410 may be generally shaped as a hollow cylinder and may extend axially inward from the first end plate 306. Additionally, as shown in FIG. 14 , a support annular wall 416 may extend axially inward from the first end wall 306.

[0081] 14 , the radially outer surface 407 of the bellows wall 316 may partially define the air plenum 400, and the radially inner surface 408 of the bellows wall 316 may partially define the first fuel plenum 317. In this manner, the bellows wall 316 may be exposed to dramatically different fluid temperatures on either side of the bellows wall 316, and the bellows wall 316 advantageously expands and / or contracts in response, thereby minimizing the thermal stresses experienced by the bundle-tube fuel nozzle 200. During operation, the air plenum 400 may receive air at an air temperature that is much higher (e.g., about 700° C. higher) than the fuel temperature of the fuel received by the first fuel plenum 317, and the bellows wall 316 may be robust to this temperature difference such that the bellows wall 316 is thermally compatible without experiencing component failure due to thermal stresses.

[0082] This specification uses examples to disclose the invention, including the best mode, and also to enable those skilled in the art to practice the invention, including making and using any device or system and performing any incorporated methods. The patentable scope of the invention is defined by the claims, and may include other examples that occur to those skilled in the art. Such other examples are intended to be within the scope of the claims if they include structural elements that do not differ from the literal language of the claims, or if they include equivalent structural elements that have no substantial differences from the literal language of the claims.

[0083] Further aspects of the present invention are provided by the subject matter of the following clause (this section will be completed by the attorney once the claims are finalized).

[0084] 1. A component formed from an additive manufacturing system, the additive manufacturing system having an axial build direction, a radial direction, and a circumferential direction, the turbomachine component including: an outer portion including a first end wall, a second end wall, and an outer band extending axially between the first and second end walls; and an inner portion disposed within the outer portion, the inner portion including a self-breaking inner band extending axially between the first and second end walls, the self-breaking inner band including a plurality of teeth disposed between the first and second end walls.

[0085] The component of any one or more of these clauses, wherein the inner portion and the outer portion are annular.

[0086] The component of any one or more of these clauses, wherein the self-rupturing inner band includes a perforated portion.

[0087] The component of any one or more of these clauses, wherein the self-rupturing inner band further includes a first solid portion extending from the first end wall to the perforated portion and a second solid portion extending from the second end wall to the perforated portion.

[0088] The component of any one or more of these clauses, wherein the perforated portion includes a plurality of walls spaced apart from one another such that a circumferential perforation is defined between each adjacent pair of walls of the plurality of walls.

[0089] The component of any one or more of these clauses, wherein the perforating portion further includes a plurality of teeth extending from each wall of the plurality of walls.

[0090] The component of one or more of these clauses, wherein at least one tooth of the plurality of teeth tapers in thickness as the at least one tooth extends axially from a respective wall of the plurality of walls.

[0091] The component of one or more of these clauses, wherein each wall and each tooth defines a constant common circumferential thickness, and each tooth tapers from a first radial thickness of the wall to a second radial thickness.

[0092] The component of any one or more of these clauses, wherein each tooth of the plurality of teeth defines a fractured surface, the fractured surface having a common circumferential thickness and a second radial thickness, the common circumferential thickness being between about 100% and about 500% of the second radial thickness at the fractured surface.

[0093] The component of any one or more of these clauses, wherein a radial perforation is defined between each tooth of the plurality of teeth.

[0094] The component of any one or more of these clauses, wherein the component is a turbomachinery component.

[0095] The turbomachine component of any one or more of these clauses, wherein the turbomachine component is a bundle-tube fuel nozzle, the bundle-tube fuel nozzle including a plurality of tubes and a bellows wall, the plurality of tubes disposed within the inner portion and extending between a first end wall and a second end wall, and the bellows wall extending between the first end wall and the self-breaking inner band.

[0096] The component of any one or more of these clauses, wherein the plurality of teeth are breakable in response to a breaking force such that the self-breaking inner band is transitionable from a connected state to a disconnected state.

[0097] The component of any one or more of these clauses, wherein the outer band and the self-rupturing inner band are each thin-walled cylindrical bodies.

[0098] The component of any one or more of these clauses, wherein each thin-walled cylinder has a wall thickness of less than 15% of the diameter of the thin-walled cylinder.

[0099] 1. A method for manufacturing a turbomachine component using an additive manufacturing system, the method comprising: irradiating a layer of powder in a powder bed to form a fused region, the powder being disposed on a build plate; disposing a subsequent layer of powder on the powder bed by passing a recoater arm over the powder bed from a first side of the powder bed; and repeating the irradiating and disposing steps until a turbomachine component is formed on the build plate, the turbomachine component comprising: an outer portion including a first end wall, a second end wall, and an outer band extending axially between the first and second end walls; and an inner portion disposed within the outer portion, the inner portion including a self-breaking inner band extending axially between the first and second end walls, the self-breaking inner band including a plurality of teeth disposed between the first and second end walls.

[0100] The method according to one or more of these clauses, further comprising applying a breaking force to the turbomachine component, whereby the self-breaking inner band is divided into a first portion extending from the first end wall and a second portion extending from the second end wall, and a gap is defined between the first portion and the second portion.

[0101] The method according to one or more of these clauses, further comprising subjecting the turbomachine component to a thermal cycle in which the temperature of one of the external portion or the internal portion is increased relative to the other of the external portion or the internal portion, whereby the self-breaking inner band is divided into a first portion extending from the first end wall and a second portion extending from the second end wall, and a gap is defined between the first portion and the second portion.

[0102] The method according to one or more of these clauses, further comprising subjecting the turbomachinery component to an operating cycle in a gas turbine, whereby the self-rupturing inner band is divided into a first portion extending from the first end wall and a second portion extending from the second end wall, and a gap is defined between the first portion and the second portion.

[0103] 1. A bundle-tube fuel nozzle comprising: a first endwall, a second endwall, an outer band extending between the first endwall and the second endwall; an inner band extending between the first endwall and the second endwall and disposed within the outer band; a bellows wall disposed between the inner band and the outer band, the bellows wall surrounding the inner band such that a first fuel plenum is annularly defined between the inner band and the bellows wall, the inner band defining a second fuel plenum in fluid communication with the first fuel plenum through one or more openings defined in the inner band; and a plurality of tubes extending axially between the first endwall and the second endwall within the second fuel plenum.

[0104] The bundle-tube fuel nozzle of any one or more of these clauses, wherein the bellows wall extends between the first end wall and the inner band.

[0105] The bundle-tube fuel nozzle of any one or more of these clauses, wherein the inner band includes a perforated portion.

[0106] The bundle-tube fuel nozzle of any one or more of these clauses, wherein the bellows wall extends from a first end connected to the first end wall to a second end connected to the inner band downstream of the perforated portion.

[0107] The bundle-tube fuel nozzle of any one or more of these clauses, wherein the bellows wall includes a plurality of angled portions and a plurality of arcuate peaks, each of the arcuate peaks being disposed between two of the angled portions.

[0108] 10. The bundle-tube fuel nozzle of claim 9, wherein an angle is defined between each of the plurality of angled portions and the axial direction, the angle being greater than about 40°.

[0109] The bundle-tube fuel nozzle of any one or more of these clauses, wherein an annular air plenum is defined between the outer band and the bellows wall.

[0110] The bundle-tube fuel nozzle of any one or more of these clauses, wherein the delimiter extends radially outward from the outer band.

[0111] The bundle-tube fuel nozzle of any one or more of these clauses, wherein an inlet to the annular air plenum is defined through the delimiter and an outlet to the annular air plenum is defined through the second end wall.

[0112] The bundle-tube fuel nozzle of any one or more of these clauses, wherein the conduit extends from the first end plate and defines a fuel inlet, the fuel inlet fluidly coupled to the fuel source and the first fuel plenum.

[0113] 1. A combustor comprising: a combustion liner defining a combustion chamber; an outer casing surrounding the combustion liner such that an annulus is defined between the combustion liner and the outer casing, the outer casing defining a head-end volume in fluid communication with the annulus; and a bundle-tube fuel nozzle at least partially disposed within the head volume, the bundle-tube fuel nozzle including: a first endwall, a second endwall, an outer band extending between the first and second endwalls; an inner band extending between the first and second endwalls and disposed within the outer band; a bellows wall disposed between the inner and outer bands, the bellows wall surrounding the inner band such that a first fuel plenum is annularly defined between the inner band and the bellows wall, the inner band defining a second fuel plenum in fluid communication with the first fuel plenum through one or more openings defined in the inner band; and a plurality of tubes extending axially between the first and second endwalls within the second fuel plenum.

[0114] The combustor of any one or more of these clauses, wherein the bellows wall extends between the first end wall and the inner band.

[0115] The combustor of any one or more of these clauses, wherein the inner band includes a perforated portion.

[0116] The combustor of any one or more of these clauses, wherein the bellows wall extends from a first end connected to the first end wall to a second end connected to the inner band downstream of the perforated portion.

[0117] The combustor of any one or more of these clauses, wherein the bellows wall includes a plurality of sloped portions and a plurality of arcuate peaks, each of the arcuate peaks being disposed between two sloped portions.

[0118] The combustor of any one or more of these clauses, wherein an angle is defined between each of the plurality of angled portions and the axial direction, the angle being greater than about 40°.

[0119] The combustor of any one or more of these clauses, wherein an annular air plenum is defined between the outer band and the bellows wall.

[0120] The combustor of any one or more of these clauses, wherein the delimiter extends radially outward from the outer band.

[0121] The combustor of any one or more of these clauses, wherein an inlet to the annular air plenum is defined through the delimiter and an outlet to the annular air plenum is defined through the second end wall.

[0122] The combustor of any one or more of these clauses, wherein a conduit extends from the first end plate and defines a fuel inlet, the fuel inlet fluidly coupled to the fuel source and the first fuel plenum. [Explanation of symbols]

[0123] 10. Gas turbine 12 Entrance Section 14 Compressor Section 16 Combustor Section 17 Combustor 18 Turbine Section 20 Exhaust Section 22 shaft 24 rotor disc 25 Compressed air 26 Rotating Blades 26 rotor blades 28 rotor disc 30 rotor blades 32 Hot gas path 33 Outer casing 34 Combustion Gas 35 End cover 36 Compressor discharge casing 37 Head end section 37 Head end volume 38 High Pressure Plenum 40 Combustion Liner 41 Circular section Zone 42 42 Combustion chamber 48 Gas fuel supply source 50 Fluid conduit 100 Additive Manufacturing System 102 Construction Plate 112 Powder bed 116 Recoater arm 118 Powder Level 120 Laser 122 Object 126 Reservoir 128 Waste container 132 Galvo Scanner 134 Recoater direction 136 Energy Beam 200 bundle tube fuel nozzle 300 Turbomachinery Components 301 Axial center line 302 External part 304 Internal part 306 First end wall, end plate 308 Second end wall, end plate 310 outer band 312 Inner band 315 Annular Plenum 316 Bellows Wall 317 First Fuel Plenum 318 First solid part 320 Second solid part 322 Perforated part 324 Second Fuel Plenum 326 Opening 328 tube 330 Entrance 331 fuel port 332 Exit 334 Premix passage 344 Gap 346 Wall 348 Circumferential Drilling 350 teeth 352 Circumferential thickness 354 first radial thickness 356 Second radial thickness 358 Fracture surface 360 base 362 Tip 364 Boundary 366 Boundary 370 base 372 Straight Surface 374 Slope 376 Radial drilling 380 Slope section 382 Arcuate top 384 angle 386 Initial slope part 388 Intermediate slope section 390 Final slope section 392 Straight section 394 Delimiter 396 Front 398 Rear 400 Annular Air Plenum 402 Entrance 404 Exit 406 Air Source 407 Radial outer surface 408 Radial inner surface 410 Conduit 412 Fuel inlet 414 Fuel Source 416 Supporting Circular Wall 1300 methods

Claims

1. A component (300) formed from an additive manufacturing system (100), the additive manufacturing system (100) having an axial build direction, a radial direction, and a circumferential direction, the turbomachinery component (300) comprising: an outer portion (302) including a first end wall (306), a second end wall (308), and an outer band (310) extending axially between said first end wall (306) and said second end wall (308); an inner portion (304) disposed within the outer portion (302), the inner portion (304) including a self-breaking inner band (312) extending axially between the first end wall (306) and the second end wall (308), the self-breaking inner band (312) including a plurality of teeth (350) disposed between the first end wall (306) and the second end wall (308).

2. The component (300) of claim 1, wherein the inner portion (304) and the outer portion (302) are annular.

3. The component (300) of claim 1, wherein the self-breaking inner band (312) includes a perforated portion (322).

4. 4. The component (300) of claim 3, wherein the self-breaking inner band (312) further includes a first solid portion (318) extending from the first end wall (306) to the perforated portion (322) and a second solid portion (320) extending from the second end wall (308) to the perforated portion (322).

5. 4. The component (300) of claim 3, wherein the perforated portion (322) includes a plurality of walls (346) spaced apart from one another such that a circumferential perforation is defined between each adjacent pair of walls (346) of the plurality of walls (346).

6. The component (300) of claim 5, wherein the perforated portion (322) further comprises a plurality of teeth (350) extending from each wall (346) of the plurality of walls (346).

7. 7. The component (300) of claim 6, wherein at least one tooth (350) of the plurality of teeth (350) tapers in thickness as the at least one tooth (350) extends axially from a respective wall (346) of the plurality of walls (346).

8. 7. The component (300) of claim 6, wherein each wall (346) and each tooth (350) defines a constant, common circumferential thickness (352), and each tooth (350) tapers from a first radial thickness (354) at the wall (346) to a second radial thickness (356).

9. 9. The component of claim 8, wherein each tooth of the plurality of teeth defines a fracture surface, the fracture surface having the common circumferential thickness and the second radial thickness, the common circumferential thickness being between about 100% and about 500% of the second radial thickness at the fracture surface.

10. The component (300) of claim 6, wherein a radial drilling (376) is defined between each tooth (350) of the plurality of teeth (350).

11. The component (300) of claim 1, wherein the component (300) is a turbomachinery component (300).

12. 12. The component of claim 11, wherein the turbomachine component is a bundle-tube fuel nozzle, the bundle-tube fuel nozzle including a plurality of tubes and a bellows wall, the plurality of tubes disposed within the interior portion and extending between the first end wall and the second end wall, and the bellows wall extending between the first end wall and the self-breaking inner band.

13. 2. The component (300) of claim 1, wherein the plurality of teeth (350) are separable in response to a breaking force such that the self-breaking inner band (312) is transitionable from a connected state to a disconnected state.

14. The component (300) of claim 1, wherein the outer band (310) and the self-breaking inner band (312) are each thin-walled cylindrical bodies.

15. 15. The component (300) of claim 14, wherein each thin-walled cylinder has a wall thickness that is less than 15% of the diameter of the thin-walled cylinder.

16. A method (1300) of manufacturing a turbomachinery component (300) using an additive manufacturing system (100), comprising: irradiating (1302) a layer of powder in a powder bed (112) to form a fused region, the powder being disposed on a build plate (102); depositing (1304) a subsequent layer of powder on the powder bed (112) by passing a recoater arm (116) over the powder bed (112) from a first side of the powder bed (112); and repeating (1306) the irradiating and providing steps until the turbomachine component (300) is formed on the build plate (102), wherein the turbomachine component (300) comprises: an outer portion (302) including a first end wall (306), a second end wall (308), and an outer band (310) extending axially between said first end wall (306) and said second end wall (308); an inner portion (304) disposed within the outer portion (302), the inner portion (304) including a self-breaking inner band (312) extending axially between the first end wall (306) and the second end wall (308), the self-breaking inner band (312) including a plurality of teeth (350) disposed between the first end wall (306) and the second end wall (308).

17. 17. The method of claim 16, further comprising applying a breaking force to the turbomachine component, whereby the self-breaking inner band splits into a first portion extending from the first end wall and a second portion extending from the second end wall, and a gap is defined between the first and second portions.

18. 17. The method of claim 16, further comprising subjecting the turbomachine component to a thermal cycle in which the temperature of one of the external portion or the internal portion is increased relative to the other of the external portion or the internal portion, whereby the self-breaking inner band is divided into a first portion extending from the first end wall and a second portion extending from the second end wall, and a gap is defined between the first portion and the second portion.

19. 17. The method of claim 16, further comprising the step of subjecting the turbomachinery component to an operating cycle in a gas turbine, whereby the self-breaking inner band is divided into a first portion extending from the first end wall and a second portion extending from the second end wall, and a gap is defined between the first portion and the second portion.

Images