Impingement panel support structure and manufacturing method

Abstract

To provide various cooling components for an integrated combustion nozzle.SOLUTION: An impingement panel (130, 134) has an impingement plate (136) disposed along an exterior surface (131, 135) of one of the inner liner segment and the outer liner segment. The impingement plate (136) defines a plurality of impingement apertures (139) that direct a coolant in discrete jets towards the exterior surface (131, 135) of the inner liner segment or the outer liner segment. The impingement panel (130, 134) includes an inlet portion (140) that extends from the impingement plate (136) to a collection duct (142). The impingement panel (130, 134) further includes a plurality of supports (194) that are spaced. The supports (194) extend between, and are coupled to, the inlet portion (140), the collection duct (142), and the impingement plate (136).SELECTED DRAWING: Figure 5

Description

[Technical Field]

[0001] The present disclosure relates generally to an integral combustion nozzle for a gas turbine engine, and more particularly to various cooling components for an integral combustion nozzle. [Background technology]

[0002] Turbomachines are utilized in various industries and applications for the purpose of energy transfer. For example, a gas turbine engine typically includes a compressor section, a combustion section, a turbine section, and an exhaust section. The compressor section gradually increases the pressure of a working fluid entering the gas turbine engine and supplies the compressed working fluid to the combustion section. The compressed working fluid and fuel (e.g., natural gas) are mixed in the combustion section and combusted in a combustion chamber to generate high-pressure and high-temperature combustion gases. The combustion gases flow from the combustion section to the turbine section, where they expand to produce work. For example, the expansion of the combustion gases in the turbine section can rotate a rotor shaft connected to, for example, a generator, to generate electricity. The combustion gases then exit the gas turbine through the exhaust section.

[0003] In many turbomachine combustors, combustion gases are channeled toward the inlet of the turbine section of the gas turbine through a hot gas path defined at least in part by a combustion liner that extends downstream from the fuel nozzles and terminates at the inlet to the turbine section. Thus, high combustion gas temperatures in the turbine section generally correspond to greater thermal and kinetic energy transfer between the combustion gases and the turbine, thereby improving the overall power output of the turbomachine. However, high combustion gas temperatures can cause erosion, creep, and / or low-cycle fatigue in various components of the combustor, thereby limiting its overall durability.

[0004] Therefore, cooling of the combustor components is necessary, which is typically achieved by routing a cooling medium, such as compressed working fluid from the compressor section, to various portions of the combustion liner. However, utilizing a majority of the compressed working fluid from the compressor section can adversely affect the overall operating efficiency of the turbomachine, as it reduces the amount of working fluid available for the turbine section. Therefore, improved systems for cooling turbomachine combustors are desired in the art, and in particular, systems that efficiently utilize compressed working fluid from the compressor would be useful. Summary of the Invention

[0005] Aspects and advantages of the assemblies and methods according to the present disclosure will be set forth in part in the description which follows, or will be obvious from the description, or may be learned by practice of the present teachings.

[0006] According to one embodiment, an impingement panel is provided. The impingement panel is configured to provide impingement cooling to an exterior surface. The impingement panel has an impingement plate disposed along the exterior surface. The impingement plate defines a plurality of impingement openings that direct coolant toward the exterior surface in discrete jets. The impingement panel includes an inlet portion extending from the impingement plate to a collection duct. At least one support is coupled to the impingement plate and at least one of the inlet portion and the collection duct.

[0007] According to another embodiment, an integrated combustor nozzle is provided. The integrated combustor nozzle includes a combustion liner extending radially between an inner liner segment and an outer liner segment. The combustion liner includes a forward end portion, an aft end portion, a first sidewall, and a second sidewall. The aft end portion of the combustion liner defines a turbine nozzle. The integrated combustor nozzle further includes an impingement panel. The impingement panel has an impingement plate disposed along an outer surface of one of the inner liner segment or the outer liner segment. The impingement plate defines a plurality of impingement openings that direct coolant in discrete jets toward the outer surface of the one of the inner liner segment or the outer liner segment. The impingement panel includes an inlet portion extending from the impingement plate to a collection duct. At least one support is coupled to the impingement plate and at least one of the inlet portion and the collection duct.

[0008] According to yet another embodiment, a method for fabricating an impingement panel is provided. The method includes irradiating a powder layer in a powder bed to form a fused region. The powder bed is disposed on a build plate. The method further includes providing 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 providing steps until an impingement panel is formed on the build plate. The impingement panel includes an impingement plate defining a plurality of impingement openings. The impingement panel further includes an inlet portion extending from the impingement plate to a collection duct. At least one support is coupled to the impingement plate and at least one of the inlet portion and the collection duct.

[0009] These and other features, aspects, and advantages of the present assembly and method 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.

[0010] A full and enabling disclosure of the present assembly, including the best mode of making and using the present system and method, directed to one of ordinary skill in the art, is set forth in this specification, which makes reference to the accompanying figures. [Brief explanation of the drawings]

[0011] [Figure 1] 1 is a schematic diagram of a turbomachine according to an embodiment of the present disclosure; [Figure 2] 1 is an upstream view of an exemplary combustion section of a turbomachine according to an embodiment of the present disclosure. [Figure 3] 1 is a perspective view of an integrated combustor nozzle from a first side according to an embodiment of the present disclosure. [Figure 4] FIG. 2 is a perspective view of an integrated combustor nozzle from a second side according to an embodiment of the present disclosure. [Figure 5] FIG. 2 is a perspective view of an integrated combustor nozzle shown with various cooling components exploded, according to an embodiment of the present disclosure; [Figure 6] 1 is a cross-sectional schematic view of an integral combustor nozzle along a radial direction of a turbomachine according to an embodiment of the present disclosure; [Figure 7] 2 is an enlarged cross-sectional view of a portion of an outer liner segment of an integral combustor nozzle according to an embodiment of the present disclosure; [Figure 8] 2 is an enlarged cross-sectional view of a portion of an inner liner segment of an integral combustor nozzle according to an embodiment of the present disclosure; [Figure 9] FIG. 2 is a plan view along a radial direction R of two impingement panels and cooling inserts isolated from other components of an integrated combustor nozzle according to an embodiment of the present disclosure. [Figure 10]2 is a cross-sectional view of a panel segment of an impingement panel along an axial direction A of a turbomachine according to an embodiment of the present disclosure. FIG. [Figure 11] FIG. 11 is a plan view of the panel segment shown in FIG. 10 along a radial direction R of the turbomachine according to an embodiment of the present disclosure. [Figure 12] FIG. 2 is a cross-sectional perspective view of a panel segment according to an embodiment of the present disclosure. [Figure 13] 13 is a plan view of a first end of the panel segment shown in FIGS. 10-12 along a central axis according to an embodiment of the present disclosure. FIG. [Figure 14] 13 is a plan view of a second end of the panel segment shown in FIGS. 10-12 taken along the central axis according to an embodiment of the present disclosure. FIG. [Figure 15] FIG. 1 is a schematic / block diagram of an additive manufacturing system for generating an object according to an embodiment of the present disclosure. [Figure 16] 1 is a flowchart of a method for fabricating an impingement panel according to an embodiment of the present disclosure. [Figure 17] FIG. 10 is a perspective view of an impingement cooling apparatus isolated from an integral combustor nozzle and positioned on a build plate with one of a row of impingement members cut away, according to an embodiment of the present disclosure. [Figure 18] FIG. 2 is an enlarged cross-sectional view of the integral combustor nozzle along a radial direction R of the turbomachine with an impingement cooling device positioned within a cavity of the integral combustor nozzle according to an embodiment of the present disclosure. [Figure 19] FIG. 10 is a cross-sectional view of a single impingement member according to an embodiment of the present disclosure. [Figure 20] FIG. 2 is an enlarged cross-sectional view of a portion of an impingement member and two adjacent impingement members along a radial direction R of a turbomachine according to an embodiment of the present disclosure. [Figure 21] FIG. 10 is a close-up view of an impingement wall standoff before removal of excess material according to an embodiment of the present disclosure. [Figure 22]FIG. 10 is a close-up view of an impingement wall standoff after removal of excess material according to an embodiment of the present disclosure. [Figure 23] 1 is a flowchart of a method for fabricating an impingement cooling device according to an embodiment of the present disclosure. [Figure 24] FIG. 2 is a perspective view of a cooling insert isolated from other components of an integrated combustor nozzle according to an embodiment of the present disclosure. [Figure 25] 1 is a cross-sectional view of a cooling insert along an axial direction A of a turbomachine according to an embodiment of the present disclosure. [Figure 26] 2 is a cross-sectional view of a cooling insert along a radial direction R of a turbomachine according to an embodiment of the present disclosure. FIG. [Figure 27] 2 is a cross-sectional view of a cooling insert along a circumferential direction C of a turbomachine according to an embodiment of the present disclosure. [Figure 28] FIG. 1 is a close-up view of two oppositely positioned cooling inserts according to an embodiment of the present disclosure. DETAILED DESCRIPTION OF THE INVENTION

[0012] Reference will now be made in detail to the embodiments of the present assembly, 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 yet 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.

[0013] 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" can be used interchangeably to distinguish one component from another and are not intended to denote the location or importance of individual components.

[0014] 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 a relative direction substantially perpendicular to the axial centerline of a particular component, the term "axially" refers to a relative direction substantially parallel and / or coaxially aligned with the axial centerline of a particular component, and the term "circumferentially" refers to a relative direction extending around the axial centerline of a particular component. Approximate terms such as "generally," "substantially," "approximately," or "about" include values ​​within plus or minus 10% of the stated value. When used in the context of an angle or direction, such terms include a range of plus or minus 10 degrees from the stated angle or direction. For example, "generally perpendicular" includes any direction, e.g., clockwise or counterclockwise, within 10 degrees of perpendicular.

[0015] The terminology used herein is for the purpose of describing particular embodiments only and is not intended to be limiting. As used herein, the singular forms "a," "an," and "the" are intended to include the plural forms as well, unless the context clearly dictates otherwise. It will be further understood that the terms "comprise" and / or "comprising," as used herein, 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 sets thereof.

[0016] 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 land-based and / or industrial gas turbines unless otherwise stated in the claims. For example, the invention described herein may be used with any type of turbomachine, including, but not limited to, a steam turbine, an aircraft gas turbine, or a marine gas turbine.

[0017] As shown, the gas turbine 10 generally includes an inlet section 12, a compressor 14 disposed downstream from the inlet section 12, a combustion section 16 disposed downstream from the compressor 14, a turbine 18 disposed downstream from the combustion section 16, and an exhaust section 20 disposed downstream from the turbine 18. Additionally, the gas turbine 10 may include one or more shafts 22 coupling the compressor 14 to the turbine 18.

[0018] During operation, air 24 flows through the inlet section 12 to the compressor 14, where the air 24 is progressively compressed, thereby providing compressed air 26 to the combustion section 16. At least a portion of the compressed air 26 is mixed with fuel 28 in the combustion section 16 and combusted to generate combustion gases 30. The combustion gases 30 flow from the combustion section 16 to the turbine 18, where energy (kinetic and / or thermal) is transferred from the combustion gases 30 to rotor blades (not shown), causing the shaft 22 to rotate. The mechanical rotational energy may then be used for various purposes, such as powering the compressor 14 and / or generating electricity. The combustion gases 30 exiting the turbine 18 may then be exhausted from the gas turbine 10 via the exhaust section 20.

[0019] FIG. 2 illustrates an upstream view of the combustion section 16 according to various embodiments of the present disclosure. As shown in FIG. 2, the combustion section 16 may be at least partially surrounded by an outer casing or compressor discharge casing 32. The compressor discharge casing 32 may at least partially define a high-pressure plenum 34 that at least partially surrounds various components of the combustor 16. The high-pressure plenum 34 is in fluid communication with the compressor 14 ( FIG. 1 ) and may receive compressed air 26 therefrom. In various embodiments, as shown in FIG. 2, the combustion section 16 includes a segmented annular combustion system 36 that includes a number of integral combustor nozzles 100 arranged circumferentially around an axial centerline 38 of the gas turbine 10, which may coincide with the gas turbine shaft 22.

[0020] FIG. 3 illustrates a perspective view of the integrated combustor nozzle 100 from a first side. Similarly, FIG. 4 illustrates a perspective view of the integrated combustor nozzle 100 from a second side in accordance with an embodiment of the present disclosure. As collectively illustrated in FIGS. 2, 3, and 4, the segmented annular combustion system 36 includes a plurality of the integrated combustor nozzles 100. As described further herein, each combustor nozzle 100 includes a first sidewall 116 and a second sidewall 118. In certain embodiments, the first sidewall is a pressure sidewall and the second sidewall is a suction sidewall based on the integration of the sidewalls with the corresponding pressure and suction sides of a downstream turbine nozzle 120. It should be understood that references made herein to a pressure sidewall and a suction sidewall represent certain embodiments, and such references are made for ease of description, and such references are not intended to limit the scope of any embodiment unless the particular context dictates otherwise.

[0021] 3 and 4 , each circumferentially adjacent pair of combustor nozzles 100 defines a respective primary combustion zone 102 and a respective secondary combustion zone 104 therebetween, thereby forming an annular array of primary combustion zones 102 and secondary combustion zones 104. The primary combustion zones 102 and secondary combustion zones 104 are circumferentially separated or fluidly isolated from adjacent primary combustion zones 102 and secondary combustion zones 104, respectively, by combustion liners 110.

[0022] 3 and 4 , each combustor nozzle 100 includes an inner liner segment 106, an outer liner segment 108, and a hollow or semi-hollow combustion liner 110 extending between the inner liner segment 106 and the outer liner segment 108. It is contemplated that multiple (e.g., two, three, four, or more) combustion liners 110 may be positioned between the inner liner segment 106 and the outer liner segment 108, thereby reducing the number of joints between adjacent liner segments that require sealing. For ease of description herein, reference will be made to a unitary combustor nozzle 100 having a single combustion liner 110 between each inner and outer liner segment 106, 108, although the liner segment to combustion liner ratio need not be 2:1. As shown in Figures 3 and 4, each combustion liner 110 includes a leading or upstream end portion 112, an aft or downstream end portion 114, a first sidewall 116, which is the pressure sidewall in the particular exemplary embodiment shown in Figure 3, and a second sidewall 118, which is the suction sidewall in the particular exemplary embodiment shown in Figure 4.

[0023] The segmented annular combustion system 36 further includes a fuel injection module 117. In the illustrated exemplary embodiment, the fuel injection module 117 includes a plurality of fuel nozzles. The fuel injection module 117 is configured to be installed in the forward end portion 112 of each combustion liner 110. For purposes of description herein, the fuel injection module 117 including a plurality of fuel nozzles may be referred to as a "bundle-tube fuel nozzle." However, the fuel injection module 117 may include or comprise any type of fuel nozzle or burner (such as a swirl fuel nozzle or a swozzle), and the claims should not be limited to a bundle-tube fuel nozzle unless otherwise specified.

[0024] Each fuel injection module 117 may extend at least partially circumferentially between two circumferentially adjacent combustion liners 110 of the respective combustor nozzle 100 and / or at least partially radially between the respective inner liner segment 106 and outer liner segment 108. During axial-staged fuel injection operation, the fuel injection modules 117 provide a flow of premixed fuel and air (i.e., first combustible mixture) to the respective primary combustion zone 102.

[0025] 3 and 4 , one or more downstream end portions 114 of the combustion liner 110 transition to a generally airfoil-shaped turbine nozzle 120 that directs and accelerates the flow of combustion products toward the turbine blades. Thus, the downstream end portion 114 of each combustion liner 110 can be considered an airfoil without a leading edge. When the integrated combustor nozzle 100 is installed within the combustion section 16, the turbine nozzle 120 can be positioned immediately upstream of a stage of turbine rotor blades of the turbine 18.

[0026] As used herein, the term "integral combustor nozzle" refers to a seamless structure that includes a combustion liner 110, a turbine nozzle 120 downstream from the combustion liner, an inner liner segment 106 (embodied by the turbine nozzle 120) that extends from the forward end 112 to the aft end 114 of the combustion liner 110, and an outer liner segment 108 (embodied by the turbine nozzle 120) that extends from the forward end 112 to the aft end 114 of the combustion liner 110. In at least one embodiment, the turbine nozzle 120 of the integral combustor nozzle 100 functions as a first stage turbine nozzle and is positioned upstream of the first stage of turbine rotor blades.

[0027] As described above, one or more of the integral combustor nozzles 100 are formed as a unitary or unitary structure or body including the inner liner segment 106, the outer liner segment 108, the combustion liner 110, and the turbine nozzle 120. The integral combustor nozzle 100 may be fabricated as a unitary or seamless component via casting, additive manufacturing (such as 3D printing), or other manufacturing techniques. Forming the combustor nozzle 100 as a single or unitary component may reduce or eliminate the need for seals between various features of the combustor nozzle 100, reduce part count and costs, and simplify or eliminate assembly steps. In other embodiments, the combustor nozzle 100 may be fabricated, such as by welding, or formed from different manufacturing techniques, with components fabricated by one technique joined to components fabricated by the same or another technique.

[0028] In certain embodiments, at least a portion or all of each integral combustor nozzle 100 may be formed from a ceramic matrix composite (CMC) or other composite material. In other embodiments, a portion or all of each integral combustor nozzle 100, and more specifically, the turbine nozzle 120 or its trailing edge, may be made from or coated with a material that is highly resistant to oxidation (e.g., coated with a thermal barrier coating).

[0029] In another embodiment (not shown), at least one of the combustion liners 110 may be tapered at a trailing edge aligned with the longitudinal (axial) axis of the combustion liner 110. That is, the combustion liners 110 may not be integrated with the turbine nozzles 120. In these embodiments, it may be desirable to have an uneven number of combustion liners 110 and turbine nozzles 120. Tapered combustion liners 110 (i.e., those without integrated turbine nozzles 120) may be used alternating with combustion liners 110 with integrated turbine nozzles 120 (i.e., integrated combustor nozzles 100) or in some other pattern.

[0030] At least one of the combustion liners 110 may include at least one cross-fire tube 122 extending through respective openings in the pressure sidewall 116 and the suction sidewall 118 of the respective combustion liner 110. The cross-fire tubes 122 facilitate flame propagation and ignition of circumferentially adjacent primary combustion zones 102 between circumferentially adjacent integral combustor nozzles 100.

[0031] In many embodiments, as shown in FIG. 3 , each combustion liner 110 may include a plurality of radially spaced-apart pressure side injection outlets 164 defined along the pressure sidewall 116, through which the pressure side fuel injectors 160 may extend ( FIG. 6 ). As shown in FIG. 4 , each combustion liner 110 may include a plurality of radially spaced-apart suction side injection outlets 165 defined along the suction sidewall 118, through which the suction side fuel injectors 161 may extend ( FIG. 6 ). Each respective primary combustion zone 102 is defined upstream of the corresponding pressure side injection outlets 164 and / or suction side injection outlets 165 of a pair of circumferentially adjacent integrated combustor nozzles 100. Each secondary combustion zone 104 is defined downstream of the corresponding pressure side injection outlets 164 and / or suction side injection outlets 165 of a pair of circumferentially adjacent integrated combustor nozzles 100. Although the multiple pressure side injection outlets 164 are illustrated in FIG. 2 as being in a common radial or injection plane relative to the axial centerline of the integrated combustor nozzle 100 or at a common axial distance from the downstream end portion 114 of the fuel injection panel 110, in certain embodiments, one or more of the pressure side injection outlets 164 may be axially staggered relative to a radially adjacent pressure side injection outlet 164, thereby offsetting the axial distance of the pressure side injection outlet 164 relative to the downstream end portion 114 of a particular pressure side injection outlet 164. Similarly, while FIG. 4 illustrates the multiple suction side injection outlets 165 in a common radial or injection plane or at a common axial distance from the downstream end portion 114 of the fuel injection panel 110, in certain embodiments, one or more of the suction side injection outlets 165 may be axially staggered relative to a radially adjacent suction side injection outlet 165, thereby offsetting the axial distance of the suction side injection outlet 165 relative to the downstream end portion 114 of a particular suction side injection outlet 165.

[0032] During operation of the segmented annular combustion system 36, it may be necessary to cool one or more of the pressure sidewall 116, the suction sidewall 118, the turbine nozzle 120, the inner liner segment 106, and / or the outer liner segment 108 of each integral combustor nozzle 100 to improve the mechanical performance of each integral combustor nozzle 100 and the overall segmented annular combustion system 36. To accommodate the cooling requirements, each integral combustor nozzle 100 may include various air passages or cavities, which may be in fluid communication with the high-pressure plenum 34 formed in the compressor discharge casing 32 and / or the premix air plenum 144 defined in each combustion liner 110.

[0033] 5 illustrates a perspective view of the integrated combustor nozzle 100 shown with various cooling components exploded, according to an embodiment of the present disclosure. In various embodiments, as shown, an interior portion of each combustion liner 110 may be defined between the pressure side wall 116 and the suction side wall 118 and may be partitioned into various air passages or cavities 124, 126 by one or more ribs 128, 129. In certain embodiments, the air cavities 124, 126 may receive air from the compressor discharge casing 32 or other cooling source. The ribs or partitions 128, 129 may extend within the interior portion of the combustion liner 110 and at least partially form or separate the multiple air cavities 124, 126. In certain embodiments, some or all of the ribs 128, 129 may provide structural support to the pressure side wall 116 and / or the suction side wall 118 of the combustion liner 110.

[0034] 5, each integral combustor nozzle 100 may include one or more outer impingement panels 130 extending along an outer surface 131 of the outer liner segment 108. The outer impingement panels 130 may have a shape corresponding to the shape or a portion of the shape of the outer liner segment 108. In many embodiments, the outer impingement panels 130 may define a plurality of impingement holes 139 defined at various locations along the outer impingement panel 130 (FIG. 7). In many embodiments, as best shown in FIGS. 3 and 4, the outer impingement panels 130 may be positioned on either side of the cavities 124, 126 to provide impingement cooling throughout the outer liner segment 108.

[0035] Similarly, each integral combustor nozzle 100 may include an inner impingement panel 134 that extends along an outer surface 135 of the inner liner segment 106. The inner impingement panel 134 may have a shape that corresponds to the shape or a portion of the shape of the inner liner segment 106. In many embodiments, as best shown in Figures 3 and 4, the inner impingement panels 134 may be positioned on either side of the cavities 124, 126 to provide impingement cooling to the entire inner liner segment 106.

[0036] 5 , one or more of the integrated combustor nozzles 100 may further include a cooling insert 400 positioned proximate the forward end 112 of the combustion liner 110 and an impingement cooling device 300 positioned proximate the aft end 114 of the combustion liner 110. As shown and described in detail below, the cooling insert may be positioned within the cavity 124 such that the cooling insert 400 is housed within the combustion liner 110 to provide cooling. Similarly, the impingement cooling device 300 may be housed within the cavity 126 such that the impingement cooling device 300 is housed within the combustion liner 110 to provide cooling. As described in more detail below, both the cooling insert 400 and the impingement cooling device 300 may be formed as a substantially hollow (or semi-hollow) structure having an opening at one or both ends that is shaped complementary to the air cavity 126. During operation, air from the compressor discharge casing 32 may flow through one or both of the cooling insert 400 and / or the impingement cooling device 300, where the air may flow through the impingement holes as discrete jets that impinge on the inner surface of the combustion liner 110, thereby allowing heat to convectively transfer from the inner surface of the combustion liner 110 to the cooling air. As described in detail below, after impinging on the inner surface of the combustion liner 110, a portion of the air that passes through the cooling insert 400 and / or the impingement cooling device 300 may flow through the combustion liner 110 toward the fuel injectors, where the air mixes with fuel and may be used for combustion in the secondary combustion zone 104. In this manner, the air used to cool the combustion liner 110 is also used to generate work in the turbine section 18, thereby increasing the overall efficiency of the gas turbine 10.

[0037] In many embodiments, two cooling inserts 400 may be installed within the air cavity 124, such as a first cooling insert 400 installed through the inner liner segment 106 and a second cooling insert 400 installed through the outer liner segment 108 as shown. Such an assembly may be useful when the integral combustor nozzle 100 includes a cross-fire tube 122 that prevents insertion of a single impingement air insert 400 through the radial dimension of the cavity 124. Alternatively, two or more impingement air inserts 400 may be positioned sequentially in the axial direction A (axial direction A is shown in FIG. 6, for example) within a given cavity, for example, on either side of the cross-fire tube 122.

[0038] FIG. 6 illustrates a cross-sectional schematic view of an integrated combustor nozzle 100 according to an embodiment of the present disclosure. As shown in FIG. 6 , the integrated combustor nozzle 100 may further include a pressure side fuel injector 160. In many embodiments, the integrated combustor nozzle 100 may include multiple pressure side fuel injectors 160 spaced apart from one another along the radial direction R. For example, each of the pressure side fuel injectors 160 may extend from an inlet 162 positioned in the combustion liner 110 proximate the suction side wall 118 to a pressure side injection outlet 164. Similarly, in many embodiments, the integrated combustor nozzle 100 may include multiple suction side fuel injectors 161 spaced apart from one another along the radial direction R. For example, each of the suction side fuel injectors 161 may extend from an inlet 166 positioned in the combustion liner 110 proximate the pressure side wall 116 to a suction side injection outlet 165. Fuel injectors 160, 161 may provide a secondary mixture of fuel and air to a secondary combustion zone 104 downstream of the primary combustion zone 102 to increase the temperature of the combustion gases before they enter the turbine section 18 and are used to generate work.

[0039] 6 , the fuel injectors 160, 161 may be positioned axially between the cooling insert 400 and the impingement cooling system 300. In certain embodiments, the pressure side fuel injector 160 may be positioned axially between the impingement cooling system 300 and the suction side fuel injector 161. Similarly, the suction side fuel injector 161 may be positioned axially between the cooling insert 400 and the pressure side fuel injector 160.

[0040] In certain embodiments, the integrated combustor nozzle 100 may include a frame 168 and ribs 128, 129. The frame 168 may extend around and support the fuel injectors 160, 161. Additionally, the frame 168 may at least partially define a path for air to travel before entering the fuel injectors 160, 161. Each of the ribs 128, 129 may extend between the pressure side wall 116 and the suction side wall 118. As shown in FIG. 6 , the ribs 128, 129 may include one or more openings defined therethrough to provide fluid communication between the fuel injectors 160, 161 and the cooling insert 400 or impingement cooling device 300.

[0041] As shown, various arrows indicate the flow paths of air within the combustion liner 110. For example, the integrated combustor nozzle 100 may further include pre-impingement air 152 and post-impingement or spent cooling air 154. As shown in FIG. 6, the pre-impingement air 152 may exit the cooling insert 400 through a first plurality of impingement openings 404 ( FIG. 24 ) and a second plurality of impingement openings 405 ( FIG. 25 ) defined in each of the walls 402, 403, respectively. Similarly, the pre-impingement air 152 may exit the impingement cooling arrangement 300 through a plurality of impingement openings 304 ( FIG. 17 ) defined in each of the impingement members 302. The impingement openings 304, 404, 405 may be sized and oriented to direct the pre-impingement air 152 in discrete jets to impinge on the inner surface 156 of the pressure side wall 116 or the inner surface 158 of the suction side wall 118. The discrete jets of air impinge on (or strike) the inner surfaces 156, 158, forming a thin boundary layer of air over the inner surfaces 156, 158, enabling optimal heat transfer between the walls 116, 118 and the air. For example, the impingement openings 304, 404, 405 may direct the pre-impingement air so that it is perpendicular to the impinging surface, e.g., the inner surfaces 156, 158 of the walls 116, 118. Because the air undergoes energy transfer and therefore has different properties when it impinges on the inner surfaces 156, 158, the air is sometimes referred to as “post-impingement air” and / or “spent cooling air.” For example, the spent cooling air 154 may have a higher temperature and lower pressure than the pre-impingement air 152 because the spent cooling air 154 is removing heat from the combustion liner 110 during the impingement process.

[0042] Referring to the flow path of the air exiting the impingement cooling apparatus 300, as shown in FIG. 6, the pre-impingement air 152 exits each of the impingement members 302 through a plurality of impingement openings 304 and impacts the inner surfaces 156, 158 of the sidewalls 116, 118. At that point, the air undergoes energy transfer by removing heat from the sidewalls 116, 118, thus becoming post-impingement air 154. The post-impingement air 154 then reverses direction and flows through gaps 172 ( FIG. 18 ) defined between the impingement members 302. As shown in FIG. 6, the impingement cooling apparatus 300 may further define collection passages 174 that receive the post-impingement air 154 from the gaps 172 defined between the impingement members 302. Both the gap 172 and the collection passages 174 preferably provide a path for the post-impingement air 154 to travel away from the pre-impingement air 152. This is advantageous because it prevents the post-impingement air 154 from impeding, i.e., flowing across and obstructing, the flow of the pre-impingement air 152, allowing the pre-impingement air 154 to maintain its high velocity and effectively cool the walls 116, 118. Once the post-impingement air 154 enters the collection passages 174, it may flow in a direction generally opposite the axial direction A, i.e., opposite the direction of the combustion gases. As shown in FIG. 6 , the post-impingement air 154 may flow from the collection passages 174, through one or more holes defined in the rib 129, around the pressure side fuel injector 160, and into the inlet 166 of the suction side fuel injector 161. In this way, all of the air flowing through the impingement cooling device 300 is utilized for both impingement cooling and combustion gas generation, minimizing the amount of wasted air from the compressor section 14 and therefore improving the overall performance of the gas turbine 10.

[0043] Referring now to the flow path of the air exiting the cooling insert 400, as shown in FIG. 6, the pre-impingement air 152 may exit the walls 402, 403 through multiple impingement openings 404, 405 and impinge against the inner surfaces 156, 158 of the sidewalls 116, 118. At that point, the air undergoes energy transfer by removing heat from the sidewalls 116, 118, thus becoming post-impingement air 154. A portion of the post-impingement air 154 then changes direction and flows in a direction opposite the axial direction A, i.e., opposite the direction of the combustion gases. As shown in FIG. 6, the post-impingement air 154 may then reverse direction and travel through a collection passage 406 defined between the walls 402, 403. The collection passage 406 may direct the post-impingement air 154 toward the pressure side fuel injector 160. In this manner, the collection passages 406 preferably provide a path for the post-impingement air 154 to travel away from the pre-impingement air 152. This is advantageous because it prevents the post-impingement air 154 from impeding, i.e., flowing across and obstructing, the flow of the pre-impingement air 152, allowing the pre-impingement air 154 to maintain its high velocity and effectively cool the walls 116, 118. Once the post-impingement air 154 enters the collection passages 406, it may be directed toward the inlets 162 of the pressure side fuel injectors 160. For example, the post-impingement air 154 may flow from the collection passages 406, through one or more openings defined in the ribs 128, around the suction side fuel injectors 161, and into the inlets 162 of the pressure side fuel injectors 160. In this way, all of the air flowing through the cooling insert 400 is utilized for both impingement cooling and combustion gas generation, minimizing the amount of wasted air from the compressor section 14 and thus improving the overall performance of the gas turbine 10.

[0044] 7 illustrates an enlarged cross-sectional view of a portion of the outer liner segment 108, and FIG. 8 illustrates an enlarged cross-sectional view of a portion of the inner liner segment 106, according to an exemplary embodiment of the integrated combustor nozzle 100. In many embodiments, the integrated combustion nozzle 100 may include an outer impingement panel 130 and an inner impingement panel 134 on either side of the combustion liner 110 to provide impingement cooling throughout the outer liner segment 108 and the inner liner segment 106.

[0045] 7 and 8 , both the outer impingement panel 130 and the inner impingement panel 134 may include impingement plates 136 disposed along the outer surfaces 131, 135 of the outer liner segment 108 and the inner liner segment 106, respectively. For example, the impingement plate 136 of the outer impingement panel 130 may be disposed along the outer surface 131, i.e., the radially outer surface, of the outer liner segment 108. Similarly, the impingement plate 136 of the inner impingement panel 134 may be disposed along the outer surface 135, i.e., the radially inner surface, of the inner liner segment 106. In the exemplary embodiment, as shown, each impingement plate 136 may be spaced apart from the respective outer surfaces 131, 135 along the radial direction R to form a cooling flow gap 138 therebetween. For example, with respect to the outer impingement panel 130, the impingement plate 136 may be spaced outward from the outer surface 131 of the outer liner segment along the radial direction R, thereby forming a cooling flow gap 138 therebetween. Similarly, the impingement plate 136 of the inner impingement panel 134 may be spaced inward from the outer surface 135 of the inner liner segment 106 along the radial direction R, thereby forming a cooling flow gap 138 therebetween.

[0046] As shown in Figures 7 and 8, various arrows may represent the flow paths of air within the impingement panels 130, 134. In an exemplary embodiment, the high-pressure plenum 34 may be in fluid communication with the cooling flow gap 138 via a plurality of impingement holes 139 defined through the impingement plate 136 along the radial direction R. Specifically, the impingement holes 139 may be sized and oriented to direct pre-impingement air 152 from the high-pressure plenum 34 in discrete jets to impinge on the outer surfaces 131, 135 of the outer liner segment 108 and inner liner segment 106. The discrete jets of pre-impingement air 152 then impinge on (or strike) the outer surfaces 131, 135, which may form a thin boundary layer of air over the outer surfaces 131, 135, enabling optimal heat transfer between the liner segments 106, 108 and the air. Because the air undergoes energy transfer and therefore has different properties as it impinges on the exterior surfaces 131, 135, the air is sometimes referred to as "post-impingement air" and / or "spent cooling air." For example, the spent cooling air 154 may have a higher temperature and lower pressure than the pre-impingement air 152 because it has removed heat from the combustion liner segments 106, 108 during the impingement process.

[0047] In the exemplary embodiment, the inlet portion 140 extends from the impingement plate 136 to the collection duct 142. As shown in FIG. 7 , the collection duct 142 may define a collection passage 144 that receives post-impingement air 154 from the cooling flow gap 138 through the inlet portion 140 and directs the post-impingement air 154 toward a low-pressure inlet 408 of a cooling insert 400 utilized in the fuel injectors 160, 161 ( FIG. 6 ). In many embodiments, as shown in FIG. 7 , the inlet portion 140 may provide a passage between the cooling flow gap 138 and the collection passage 144. For example, the inlet portion 140 may extend directly from the impingement plate 136 to the collection duct 142 such that the inlet portion 140 fluidly couples the cooling flow gap 138 directly to the collection passage 144. In various embodiments, as shown in FIG. 10 , the inlet portion 140 may include sidewalls 150 that are spaced apart from one another. The side walls 150 may extend axially along the impingement plate 136 parallel to one another to define elongated slot-shaped openings 188 (FIG. 11) through the impingement plate 130 for the passage of post-impingement air 154.

[0048] 10 , each collection duct 142 may have a cross-sectional shape that defines a rectangular area. For example, each collection duct 142 may include a radially inner wall 146, a radially outer wall 148, and a sidewall 141 extending between the radially inner wall 146 and the radially outer wall 148. In certain embodiments, the sidewalls 141 of the collection ducts 142 may be parallel to one another and longer than the radially inner / outer walls 146, 148, which advantageously allows the collection ducts 142 to have a large collection area without overlapping with the impingement holes 139 and impeding airflow between the high-pressure plenum 34 and the cooling flow gap 138. In other embodiments (not shown), the collection ducts may have any suitable cross-sectional shape, such as a circle, an oval, a diamond, a square, or any other suitable polygon, and thus should not be limited to any particular cross-sectional shape unless specifically recited in the claims.

[0049] As shown in FIG. 10 , the inlet portion 140 may define a first width 176, and the collection duct 142 may define a second width 178. More specifically, the first width 176 may be defined between the sidewalls 150 of the inlet portion 140. Similarly, the second width 178 of the collection duct 142 may be defined between the sidewalls 141 of the collection duct 142. To maximize the amount of area available for impingement cooling by the impingement plate 136, it may be advantageous to make the first width 176 as small as possible relative to the second width 178 of the collection duct 142. For example, in an exemplary embodiment, the second width 178 of the collection duct 142 may be greater than the first width 176 of the inlet portion 140.

[0050] In many embodiments, as shown in FIG. 9 , the collection duct 142 may be a first collection duct 142′, and the impingement panel 130 may further include a second collection duct 142″ extending from the impingement panel 130. As shown, the first collection duct 142′ and the second collection duct 142″ may be spaced apart from one another and may extend generally parallel to one another in the axial direction A. In such embodiments, each collection duct 142′, 142″ may be coupled to the impingement plate 136 via a respective inlet portion 140 that provides a passage between the cooling flow gap 138 and the collection passages 144. For example, the respective inlet portions 140 may each extend directly from the impingement plate 136 to the collection duct 142 so as to directly fluidly couple the cooling flow gap 138 to the respective collection passage 144.

[0051] FIG. 9 illustrates a plan view along the radial direction R of two impingement panels 131 and cooling inserts 400, isolated from other components of the integrated combustor nozzle. As shown in FIG. 9, the impingement panel 131 may represent either or both of the outer impingement panel 130 and / or the inner impingement panel 134. In many embodiments, each of the impingement panels 130 may be coupled to a low-pressure inlet 408 of the cooling insert 400. In certain embodiments, each of the collection ducts 142 may be coupled to the low-pressure inlet 408 via a connecting duct 180. In some embodiments (not shown), the collection ducts 142 may be directly coupled to the respective low-pressure inlets 408 of the cooling inserts 400. As described in detail below, the low-pressure inlets 408 of the cooling inserts 400 may be in direct fluid communication with the collection passages 406, and therefore in fluid communication with the suction side fuel injectors 161. In this manner, the collection duct 142 advantageously provides a passageway for the post-impingement air 154 to travel to the fuel injectors so that the air can be used to generate combustion gases within the secondary combustion zone 104.

[0052] In many embodiments, the impingement panel 130 may be a single body extending continuously from its forward end to its aft end. However, in an exemplary embodiment, as shown in FIG. 9 , the impingement panel 130 may include multiple panel segments 182 coupled together. For example, in many embodiments, the impingement panel 130 may include two panel segments 182, such as a forward segment 184 and an aft segment 186, coupled together. In other embodiments, the impingement panel may include three or more segments, such as a forward segment 184, a middle segment 185, and an aft segment 186. In such embodiments, the forward segment 184 and the aft segment 186 may each be independently coupled to the middle segment 185, as shown. Dividing the impingement panel 130 into panel segments 182 advantageously allows for an increased number of impingement panels 130 to be produced at one time, such as by additive manufacturing, thereby saving on manufacturing costs.

[0053] 11 , the inlet portion 140 of each panel section 182 may further define an elongated slot opening 188 through the respective impingement plate 136 to allow post-impingement air 154 to flow from the cooling gap to the collection duct 142. In some embodiments (not shown), the elongated slot opening 188 may be continuous between panel segments 182.

[0054] 9 , each of the collection ducts 142 may converge in cross section from the forward end 190 to the aft end 192, i.e., in the axial direction A. More specifically, the sidewalls 141 of the collection ducts 142 may converge toward each other from the forward end 190 to the aft end of the impingement panel 130, thereby gradually decreasing the second width 178 and cross-sectional area of ​​the collection duct 142 as it extends in the axial direction A. The gradually decreasing cross-sectional area of ​​the collection duct 142 from the forward end 190 to the aft end 192 of the impingement panel 130 may advantageously influence the post-impingement air 154 to flow toward the cooling insert 400, i.e., in the counter-axial direction.

[0055] During operation, the collection duct 142 can receive spent cooling air from the cooling flow gap 138. As used herein, the terms “post-impingement air” and / or “spent cooling air” refer to air that has already impinged on a surface and thus undergone energy transfer. For example, the spent cooling air can have a higher temperature and lower pressure than before impinging on the exterior surfaces 131, 135, making it less ideal for further cooling within the integrated combustion nozzle. However, the collection duct 142 advantageously collects the spent cooling air and directs it toward one or more fuel injectors, e.g., the fuel injection module 117 and / or one or both of the fuel injectors 160 and 161, for use in either the primary combustion zone 102 or the secondary combustion zone 104. In this manner, the impingement panel 130 efficiently utilizes air from the high-pressure plenum 34 by first utilizing the air to cool the liner segments 106, 108 and then using the air to generate combustion gases that power the turbine section 18.

[0056] In many embodiments, each of the panel segments 182 may be integrally formed as a single component. That is, for example, each of the subcomponents, such as the impingement plate 136, the inlet portion 140, the collection duct 142, and any other subcomponents of the panel segment 182, may be manufactured together as a single body. In the exemplary embodiment, this can be done by utilizing the additive manufacturing system 1000 described herein. However, in other embodiments, other manufacturing techniques, such as casting or other suitable techniques, may be used. In this regard, utilizing additive manufacturing methods, each panel segment 182 of the impingement panel 130 may be integrally formed as a single, continuous piece of metal and, therefore, may include fewer subcomponents and / or joints compared to conventional designs. The integral formation of each panel segment 182 through additive manufacturing can advantageously improve the overall assembly process. For example, integral formation reduces the number of separate parts that must be assembled, thereby reducing the associated time and overall assembly costs. Additionally, existing issues with, for example, leakage, joint quality between separate parts, and overall performance may be advantageously reduced. In some embodiments, the entire impingement panel 130 may be integrally formed as a single component.

[0057] Figure 10 illustrates a cross-sectional view of a panel segment 182 of an impingement panel 130 along an axial direction A, and Figure 11 illustrates a plan view of the panel segment 182 along a radial direction R, in accordance with an embodiment of the present disclosure. It will be understood that the features of the panel segment 182 illustrated in Figures 10 and 11 may be incorporated into any of the panel segments described herein, such as the forward segment 184, the middle segment 185, and / or the aft segment 186.

[0058] As shown in FIGS. 10 and 11 , the panel segment 182 may further include one or more supports 194 extending between and integrally formed with the inlet portion 140, the collection duct 142, and the impingement plate 136 to provide structural support. In various embodiments, each support 194 may be substantially shaped as a flat plate extending between the impingement plate 136 and the collection duct 142. In particular embodiments, each support 194 may extend from a first end 196 integrally formed with the impingement plate 136 to a second end 198 integrally formed with the collection duct 142. In exemplary embodiments, the supports 194 may be fixedly coupled to the panel segment 182; for example, the supports 194 may be separate components that are welded and / or brazed to the panel segment 182. Utilizing the supports 194 in this manner provides additional structural integrity to the collection duct 142, which advantageously prevents damage to the impingement panel 130 due to vibration forces of the gas turbine 10 during operation.

[0059] In certain embodiments, each of the supports 194 includes a first side 197 and a second side 199 that extend between a first end 196 and a second end 198 of each of the supports 194, i.e., between the impingement plate 136 and the collection duct 142. As shown in FIG. 10 , the first end 196, the second end 198, the first side 197, and the second side 199 may collectively define a perimeter of the support 194. In many embodiments, the first side 197 of the support 194 extends along and is integrally formed with one of the side walls 150 of the inlet portion 140. In an exemplary embodiment, the second side 199 of the support 194 may be generally straight, extending from the impingement plate 136 at an angle 200.

[0060] For example, in many embodiments, the second side 199 of each support 194 can form an angle 200 with the impingement plate 136 of between about 10° and about 75°. In other embodiments, the second side 199 of each support 194 can form an angle 200 with the impingement plate 136 of between about 20° and about 65°. In various embodiments, the second side 199 of each support 194 can form an angle 200 with the impingement plate 136 of between about 30° and about 55°. In certain embodiments, the second side 199 of each support 194 can form an angle 200 with the impingement plate 136 of between about 40° and about 50°.

[0061] In the exemplary embodiment, the angle 200 of the second side 199 may advantageously provide additional structural support to the impingement panel 130, thereby preventing vibration damage to the impingement panel 130 during operation of the gas turbine 10. Additionally, the angle 200 of the second side 199 may provide additional structural support to the collection duct 142 during the additive manufacturing process of the impingement panel 130, advantageously reducing the likelihood of distortion and / or defects in the impingement panel 130. For example, the angle 200 of the second side 199 relative to the impingement plate 136 described herein may prevent the support 194 from overhanging, i.e., having excessive thickness-to-thickness variation, while being fabricated using the additive manufacturing system 1000 ( FIG. 15 ). As a result, the impingement panel 130, which may be difficult to manufacture via conventional means due to its complex geometry, may be fabricated using the additive manufacturing system 1000 without causing defects or deformation in the part.

[0062] 11 , each of the supports 194 may form an angle 202 with the inlet portion 140 (shown in dashed lines in FIG. 11 ). More specifically, each of the supports 194 may form an angle 202 with the sidewall 150 of the inlet portion 140. In many embodiments, the angle 202 may be oblique, which preferably allows the supports 194 to extend further along the impingement plate 136. However, in other embodiments (not shown), one or more of the supports 194 may be perpendicular to the inlet portion 140.

[0063] In various embodiments, the angle 202 between the sidewall 150 of the inlet portion 140 and the support 194 can be between about 10° and about 90°. In other embodiments, the angle 202 between the sidewall 150 of the inlet portion 140 and the support 194 can be between about 20° and about 70°. In certain embodiments, the angle 202 between the sidewall 150 of the inlet portion 140 and the support 194 can be between about 30° and about 60°. In many embodiments, the angle 202 between the sidewall 150 of the inlet portion 140 and the support 194 can be between about 40° and about 50°.

[0064] 11 , the panel segment 182 may further include a central axis 206 that may be generally parallel to the sidewall 150 of the inlet portion 140. In many embodiments, when the panel segment 182 is installed in the integrated combustor 100, the central axis 206 may extend coaxially with the axial direction A of the gas turbine 10. In other embodiments, the central axis 206 may extend generally parallel to the axial direction A when the panel segment is installed in the integrated combustor nozzle 100.

[0065] Figure 12 shows a cross-sectional perspective view of a panel segment 182 according to an embodiment of the present disclosure. The panel segment 182 can extend along a central axis 206 (Figure 11) from a first end 208 to a second end 210. Figure 13 shows a top view of an exemplary embodiment of the first end 208 of the panel segment 182 along the central axis 206, and Figure 14 shows the second end 210 of the panel segment 182 along the central axis 206.

[0066] As shown in FIG. 13 , the first end 208 of the panel segment 182 includes a flange 212 extending from the impingement panel. In various embodiments, the flange 212 may be a generally flat plate extending from the first end 208 of the panel segment 182. More specifically, the flange 212 may be perpendicular to and extend away from the impingement plate 136, the inlet portion 140, and the collection duct 142 at the first end 208 of the panel segment 182 to define a connecting surface 213 ( FIG. 13 ). The connecting surface 213 advantageously allows multiple panel segments 182 to be fixedly coupled to one another by means such as welding, brazing, or other suitable methods. In many embodiments, the flange 212 also increases the overall stiffness and structural integrity of the panel segment 182, thereby preventing vibration damage that may occur to the components during operation of the gas turbine 10.

[0067] In many embodiments, the flange 212 may be integrally formed with the panel segment 182, such that the collection plate 136, the inlet portion 140, the collection duct 142, and the flange 212 may be a single continuous piece of metal. In such embodiments, the flange 212 may also provide manufacturing advantages. For example, the flange 212 generally surrounds features of the panel segment 182 and provides additional structural support for the collection duct 142 during the additive manufacturing process.

[0068] As shown in FIG. 14 , in some embodiments, the second end 210 of the impingement panel 182 may not include the flange 212 integrally formed therewith, as is the case with the first end 208. An end plate 211 may be attached to and fixedly coupled to the second end 210, as indicated by the dashed line in FIG. 14 . For example, the end plate 211 may be a completely separate component from the impingement panel segment 182. In many embodiments, the end plate 211 may be welded or brazed to the second end 210 after fabrication of the impingement panel segment 182 is completed. The end plate 211 fixedly coupled to the second end 210 may have a substantially similar geometric shape to the flange 212, but is a separate component rather than integrally formed. The end plate 211 may function to couple the second end 210 of the impingement panel segment 182 to the first end 208 of an adjacent impingement panel segment (as shown in FIG. 9 ). In the exemplary embodiment, the end plate 211 of the impingement panel segment 182 may be fixedly coupled to the flange 212 of an adjacent impingement panel segment 182. Joining the impingement panel segments 182 in this manner may be advantageous because the end plate 211 and flange 212 have relatively flat, smooth surfaces that provide easy, error-free welding therebetween. In other embodiments, both the first end 208 and the second end 210 may include a flange 212, and the flange 212 of the first end 208 of the panel segment 182 may be fixedly coupled to the flange 212 of the second end 210 of the adjacent panel segment 182.

[0069] To illustrate an example of an additive manufacturing system and process, FIG. 15 shows a schematic / block diagram of an additive manufacturing system 1000 for producing an object 1220, such as the panel segment 182, cooling insert 400, and / or impingement cooling device 300 described herein. FIG. 15 may represent an additive manufacturing system configured for direct metal laser sintering (DMLS) or direct metal laser melting (DMLM). The additive manufacturing system 1000 fabricates an object, such as the object 1220 (which may represent the panel segment 182, cooling insert 400, and / or impingement cooling device 300 described herein). For example, the object 1220 may be fabricated layer-by-layer by sintering or melting a powder material (not shown) using an energy beam 1360 generated by a light source, such as the laser 1200. The powder to be melted by the energy beam is supplied by a reservoir 1260 and uniformly distributed on the build plate 1002 using a recoater arm 1160, maintaining the powder at level 1180 and removing excess powder material extending above the powder level 1180 to a waste container 1280. The energy beam 1360 sinters or fuses a cross-sectional layer of the object being built under the control of a galvo scanner 1320. The build plate 1002 is lowered, and another layer of powder is distributed on the build plate and the object being built, followed by subsequent powder melting / sintering by the laser 1200. The process is repeated until the object 1220 is fully constructed from the fused / sintered powder material. The laser 1200 can be controlled by a computer system including a processor and memory. The computer system can determine a scanning pattern for each layer and control the laser 1200 to irradiate the powder material according to the scanning pattern. After fabrication of the object 1220 is complete, various post-processing procedures can be applied to the object 1220. Post-processing procedures include, for example, removing excess powder by blowing or suction. Other post-processing procedures include stress relaxation processes. Additionally, thermal and chemical post-processing procedures can be used to finish the object 1220.

[0070] FIG. 16 is a flowchart of a series of steps 1602-1606 defining a method 1600 for fabricating an impingement panel (e.g., one of the impingement panels 130, 131, 134 described herein) according to an embodiment of the present disclosure. The method 1600 can be performed using an additive manufacturing system, such as the additive manufacturing system 1000 described herein or another suitable system. As shown in FIG. 16 , the method 1600 includes a step 1602 of irradiating a powder layer in a powder bed 1120 to form a fused region. In many embodiments, the powder bed 1120 can be positioned on the build plate 1002 such that the fused region is fixedly attached to the build plate 1002, as shown in FIG. 15 . The method 1600 can include a step 1604 of providing a subsequent powder layer onto the powder bed 1120 from a first side of the powder bed 1120. The method 1600 further includes a step 1606 of repeating steps 1602 and 1604 until an impingement panel is formed in the powder bed 1120.

[0071] 17 shows a perspective view of the impingement cooling device 300 isolated from the integrated combustor nozzle and positioned on the build plate 1002 with one of the rows of impingement members cut away. As described below, the impingement cooling device 300 can be additively manufactured on the build plate 1002, for example, by the additive manufacturing system 1000. FIG. 17 illustrates the impingement cooling device 300 prior to removal from the build plate 1002 and installation on the integrated combustor nozzle 100, in accordance with an embodiment of the present disclosure.

[0072] 17 , the impingement cooling device 300 may extend from a first end 306 to a second end 308 in a radial direction R, which may coincide with the build direction. In many embodiments, the impingement cooling device 300 includes a plurality of impingement members 302 arranged in a first row 320 of impingement members 302 and a second row 322 of impingement members 302. Each impingement member 302 in the first row 320 of impingement members 302 may extend from a first flange 310 at the first end 306 of the impingement cooling device 300 to a respective closed end 312 at the second end 308. Similarly, each impingement member 302 in the second row 322 of impingement members 302 may extend from a second flange 311 at the first end 306 of the impingement cooling device 300 to a respective closed end 312 at the second end 308. In this manner, the first row 320 and the second row 322 of impingement members 302 may each be a single component that can move relative to one another during installation in the cavity 126, which advantageously allows the distance between the rows 320, 322 of impingement members 302 and the walls 116, 118 to be set independently of one another.

[0073] In other embodiments, each impingement member 302 may be its own entirely separate component capable of moving relative to the other impingement members 302 within the impingement cooling arrangement 300. In such embodiments, each impingement member 302 may extend from a respective flange. In embodiments in which each impingement member 302 is a separate component, the impingement members may be individually installed (i.e., one at a time) within the integrated combustor nozzle, and each standoff 356, 358 may function to ensure that an appropriately sized gap is disposed between each impingement member 302 during both installation and operation of the impingement members 302.

[0074] In the exemplary embodiment, each of the impingement members 302 may be a substantially hollow body extending from a respective opening 313 defined in the flanges 310, 311 to a respective closed end 312 ( FIG. 19 ). While the embodiment of FIG. 17 illustrates the impingement cooling apparatus 300 having eleven impingement cooling members 302, the impingement cooling apparatus 300 may have any number of impingement members 302, such as four, six, eight, twelve, fourteen, or more. In various embodiments, as shown in FIG. 17 , each impingement member 302 of the plurality of impingement members 302 may be spaced apart from an immediately adjacent impingement member 302 to define a gap 172 for post-impingement air 154 to flow between the impingement members 302 and into the collection passage 174 ( FIG. 6 ). In many embodiments, multiple impingement openings 304 may be defined in each impingement member 302 of the multiple impingement members 302 .

[0075] FIG. 18 illustrates an enlarged cross-sectional view of the integrated combustor nozzle 100 along the radial direction R with the impingement cooling device 300 positioned within the cavity 126. As shown in FIG. 18 , the integrated combustor nozzle 100 may further include a camber axis 318 that may be defined midway between the pressure sidewall 116 and the suction sidewall 118. For example, the camber axis 318 may be curved and / or contoured to correspond to the curvature of the pressure sidewall 116 and the suction sidewall 118. A lateral direction T may be defined orthogonal to the camber axis 318. More specifically, the lateral direction T may extend outward from and perpendicular to a line tangent to the camber axis 318 at each location along the camber axis 318.

[0076] In certain embodiments, each impingement member 302 of the plurality of impingement members 302 includes an impingement wall 314 spaced apart from a solid wall 316. In an exemplary embodiment, a plurality of impingement openings may be defined in the impingement wall 314 to direct the pre-impingement air 152 toward the inner surfaces 156, 158 of the walls 116, 118 ( FIG. 6 ). The solid wall 316 may be disposed opposite the impingement wall 314. In many embodiments, the solid wall 316 of each respective impingement member 302 may be directly outward of the camber axis 318 along the lateral direction T, such that the solid walls 316 of the impingement members 302 collectively define the boundary of the collection passage 174. As used herein, the term “solid” may refer to one or more walls that are impermeable so that air or other fluids cannot pass through. For example, each of the solid walls 316 may be free of impingement openings, holes, or voids that allow the pre-impingement air 152 to escape to ensure that all air is directed toward the inner surfaces 156, 158 of the walls 116, 118 for cooling.

[0077] 18 , the plurality of impingement members 302 may include a first row 320 of impingement members 302 disposed proximate the pressure sidewall 116 and a second row 322 of impingement members 302 disposed proximate the suction sidewall 118. For example, the first row 320 and the second row 322 of impingement members may be disposed on opposite sides of the camber axis 318 so as to be spaced apart in the lateral direction T. As shown in FIG. 18 , the collection passage 174 may be defined between the first row 320 and the second row 322 of impingement members 302. More specifically, the collection passage 174 may be collectively defined between the solid walls 316 of the first row 320 of impingement members 302 and the solid walls 316 of the second row 322 of impingement members 302. As shown in FIG. 6 and described above, the collection passage 174 may function to receive and direct the post-impingement air 154 toward a fuel injector, such as the suction side fuel injector 161 (FIG. 6).

[0078] In certain embodiments, the first row 320 of impingement members 302 and the second row 322 of impingement members 302 diverge from one another from the aft end 324 to the forward end 326 of the impingement cooling device 300, i.e., opposite the direction of the combustion gases in the combustion zones 102, 104. For example, the first row 320 of impingement members 302 and the second row 322 of impingement members 302 diverge from one another laterally from the aft end 324 to the forward end 326 of the impingement cooling device 300. In this manner, the lateral distance between the impingement members 302 of the first row 320 and the impingement members 302 of the second row 322 may gradually increase from the aft end 324 to the forward end 326, thereby influencing the post-impingement air 154 to move toward the suction side fuel injectors 161.

[0079] 18 , the impingement wall 314 of each respective impingement member 302 in the first row 320 may be contoured to correspond to a portion of the pressure side wall 116 such that the impingement walls 314 of the first row 320 collectively correspond to the contour of the pressure side wall 116. Similarly, the impingement wall 314 of each respective impingement member 302 in the second row 322 may be contoured to correspond to a portion of the suction side wall 118 such that the impingement walls 314 of the second row 322 collectively correspond to the contour of the suction side wall 118. Matching the contours of the walls 116, 118 advantageously maintains a desired lateral distance from the respective walls 116, 118. In many embodiments, the lateral distance between the impingement wall 314 and the respective walls 116, 118 may be substantially constant.

[0080] In certain embodiments, each impingement member 302 of the plurality of impingement members 302 may include a first solid sidewall 328 and a second solid sidewall 330 that each extend between the impingement wall 314 and the solid wall 316. As shown in FIG. 18 , the first solid sidewall 328 and the second solid sidewall 330 of each impingement member 302 may be spaced apart and disposed opposite one another. In various embodiments, the first solid wall 328 and the second solid sidewall 330 of each impingement member 302 may be generally parallel to one another in the lateral direction T. As shown in FIG. 18 , the first solid sidewall 328, the second solid wall 330, the impingement wall 314, and the solid wall 316 of each impingement member of the plurality of impingement members collectively define an interior volume 332 that is in fluid communication with the high-pressure plenum 34. In the exemplary embodiment, each of the impingement members 302 may define a generally rectangular cross-sectional area. However, in other embodiments (not shown), each of the impingement members 302 may define a cross-sectional area having a circular, diamond-shaped, triangular, or other suitable cross-sectional shape.

[0081] In certain embodiments, as shown in FIGS. 6 , 18 , and 20 , gaps 172 may be defined between immediately adjacent impingement members 302, which advantageously provides a path for post-impingement air 154 to travel to the collection passage 174. In various embodiments, each of the gaps 172 may be defined directly between the first sidewall 328 of an impingement member and the second sidewall 330 of the immediately adjacent impingement member 302. In this manner, each impingement member 302 of the plurality of impingement members 302 partially defines at least one gap 172. As shown in FIG. 18 , each of the gaps 172 may be defined between the first sidewall 328 of an impingement member 302 and the second sidewall 330 of the adjacent impingement member 302 in a direction generally parallel to the camber axis 318 at the respective location. In other embodiments (not shown), each impingement member 302 may define a diamond-shaped cross-sectional area. In such an embodiment, the first sidewall 328 and the second sidewall 330 may be angled relative to the camber axis, which may advantageously reduce the pressure drop of the impingement air.

[0082] 19 illustrates a cross-sectional view of a single impingement member 302 along the camber axis 318. FIG. 20 shows an enlarged cross-sectional view of a portion of the impingement member 302 and two adjacent impingement members 302 along the radial direction R in accordance with an embodiment of the present disclosure. It should be understood that the features of the impingement member 302 shown in FIGS. 19 and 20 may be incorporated into any of the impingement members 302 of the multiple impingement members 302 described herein. In an exemplary embodiment, as shown in FIGS. 19 and 20, the impingement member 302 may further include a first protrusion 334, a second protrusion 335, and a plurality of cross-supports 346 extending therebetween. In many embodiments, the first protrusion 334 may be disposed on the impingement wall 314, the second protrusion 335 may be disposed on the solid wall 316, and each of the multiple cross-supports 346 may extend from the first protrusion 334 through the interior volume 332 to the second protrusion 335. Each of the protrusions 334, 335 may extend from the respective wall 314, 316 toward an axial centerline 336 ( FIG. 19 ) of the impingement member 302. More specifically, the first protrusion 334 may extend directly from an inner surface 338 of the impingement wall 314 toward the axial centerline 336. Similarly, the second protrusion 335 may extend directly from an inner surface 340 of the solid wall 316 toward the axial centerline 336. In various embodiments, the first protrusion 334 may extend radially along the entire length of the impingement wall 314 , for example, between the open end 313 and the closed end 312 of the impingement member 302 .

[0083] In certain embodiments, as shown in FIG. 20 , each protrusion 334, 335 may include a first portion 342 extending generally perpendicularly between the respective wall 314, 316 and the second portion 344. The second portion 344 of each protrusion 334, 335 may extend generally perpendicularly to the respective first portion 342 such that the protrusions 334, 335 each define a T-shaped cross-section. The protrusions 334, 335 advantageously improve the stiffness of each of the impingement members 302 and, therefore, the overall stiffness of the impingement cooling device 300. Increasing the stiffness of the impingement cooling device 300 can prevent damage caused by vibratory forces of the gas turbine 10 during operation. For example, the protrusions 334, 335 can impart a more desirable natural frequency to the impingement cooling device 300 to prevent failure of the impingement cooling device 300 caused by micro-vibrations of the integrated combustion nozzle 100.

[0084] As shown in FIGS. 19 and 20 , each of the cross-supports 346 can include a first support bar 348 and a second support bar 350 that intersect one another at an intersection 352 ( FIG. 19 ) located within the interior volume 332 of the impingement member 302. In certain embodiments, the first support bar 348 and the second support bar 350 of each of the cross-supports 346 can extend between the first projection 334 and the second projection 335. More specifically, the first support bar 348 and the second support bar 350 of each of the cross-supports 346 can extend directly between the second portion 344 of the first projection 334 and the second portion 344 of the second projection 335. In other embodiments (not shown), the first support bar 348 and the second support bar 350 of each of the cross-supports can extend directly between the interior of the impingement wall and the interior of the solid wall, such that no projections are present.

[0085] In many embodiments, as shown in FIG. 19 , the first support bar 348 and the second support bar 350 may each form an angle 354 with the flange 310 that is oblique, i.e., neither parallel nor perpendicular. For example, in some embodiments, the first support bar 348 and the second support bar 350 may each form an angle 354 with the flange 310 of between about 15° and about 75°. In other embodiments, the first support bar 348 and the second support bar 350 may each form an angle 354 with the flange 310 of between about 25° and about 65°. In various embodiments, the first support bar 348 and the second support bar 350 may each form an angle 354 with the flange 310 of between about 35° and about 55°. In certain embodiments, the first support bar 348 and the second support bar 350 may each form an angle 354 with the flange 310 of between about 40° and about 50°. The angle 354 advantageously provides additional structural integrity and internal bracing to each of the impingement members 302, preventing damage from the vibratory forces of the gas turbine 10. Additionally, as described below, the angle 354 of the support bars 348, 350 allows the impingement members 302 to be additively manufactured without defects or deformation. When additively manufactured layer by layer, such as using the additive manufacturing system 1000 described herein, the angle of the support bars 348, 350 advantageously prevents potentially harmful overhangs of the cross supports 346, which could cause deformation and / or total collapse of the component. For example, support bars that extend vertically across the impingement member 302 may be difficult and / or impossible to manufacture using an additive manufacturing system. Therefore, the angle 354 between the support bars 348, 350 and the flange 310 is favorable.

[0086] In many embodiments, as collectively shown in FIGS. 17-20 , the impingement cooling apparatus 300 may further include standoffs 356, 358 extending from each of the impingement members 302. The standoffs 356, 358 may be shaped as substantially flat plates extending outward from the impingement members 302. In many embodiments, the standoffs may space each impingement member 302 from surrounding surfaces, such as adjacent impingement members 302 and / or the walls 116, 118 of the combustion liner 110. The standoffs 356, 358 may be configured to maintain the impingement members 302 at a desired distance from surrounding surfaces to optimize impingement cooling of the combustion liner 310 and recirculation of the post-impingement air 154 into the collection passages 174.

[0087] 17 , in many embodiments, at least one sidewall standoff 356 and at least one impingement wall standoff 358 may be positioned proximate the flanges 310, 311 on each impingement member 302. In various embodiments, at least one sidewall standoff 356 and at least one impingement wall standoff 358 may be positioned proximate the closed end 312 of each impingement member 302 of the plurality of impingement members 302. Locating the standoffs 356, 358 proximate the first end 306 and the second end 308 of the impingement cooling device 300 may advantageously provide more uniform support and spacing between adjacent impingement members 302 and between the impingement members 302 and the walls 116, 118 of the combustion liner 110.

[0088] 20 , the sidewall standoffs 356 may each extend from the first solid sidewall 328 of an impingement member 302 to the second solid sidewall 330 of an adjacent impingement member 302, connecting them. In an exemplary embodiment, the length of the sidewall standoffs 356 may set the distance of the gap 172 and connect adjacent impingement members 302 to one another. For example, a row of impingement members 302, such as the first row 320 and / or the second row 322, may be connected to adjacent impingement members 302 in that row via one or more of the sidewall standoffs 356. In this manner, the sidewall standoffs 356 function to maintain adequate spacing between the impingement members 302. Additionally, the sidewall standoffs 356 advantageously prevent deformation of the relatively slender impingement members 302 during the additive manufacturing process by providing additional structural support to the impingement cooling apparatus 300.

[0089] 18 , the impingement wall standoff 358 can function to maintain the proper spacing between the impingement member 302 and one of the walls 116, 118 of the combustion liner 110. For example, in the exemplary embodiment, the impingement wall standoff 358 can extend from the impingement wall 314 and contact one of the walls 116, 118 of the combustion liner 310, which may be one of the first sidewall 116 or the second sidewall 118 of the combustion liner 310. For example, unlike the sidewall standoff 356, the impingement wall standoff 358 is not coupled at both ends, but is integrally formed with the impingement wall 314 at one end and contacts the inner surface of either the pressure side wall 116 or the suction side wall 118 when the impingement cooling device 300 is installed in the combustion liner 110. In this manner, the impingement wall standoff 358 can be removably coupled to the combustion liner 110. In the exemplary embodiment, the length of sidewall standoff 358 may set the distance of the gap disposed between impingement wall 314 and wall 116 or 118 of combustion liner 310 .

[0090] 21 and 22 show close-up views of an impingement wall standoff 358 extending from the impingement wall 314 of the impingement member 302 to one of the walls 116, 118 (shown in dashed lines) of the combustion liner 310, in accordance with an embodiment of the present disclosure. More specifically, FIG. 20 shows the impingement wall standoff 358 immediately after being manufactured by, for example, the additive manufacturing system 1000, but prior to post-processing. In many embodiments, each of the impingement wall standoffs can be manufactured to have excess material or length 360, as indicated by the length 360 of the standoff 358 extending beyond the wall 116 or 118. As shown in FIG. 21 , the excess material or length 360 of the standoff 358 can be removed to maintain a desired tolerance between the impingement wall 314 and the walls 116, 118 for optimal cooling performance.

[0091] While FIG. 22 illustrates an exemplary embodiment of the impingement wall standoffs 358 of the impingement cooling apparatus 300, FIG. 21 may represent various other standoffs disclosed herein (such as standoffs disposed on the impingement panel 130 and / or standoffs disposed on the cooling insert 400).

[0092] In certain embodiments, each row 320, 322 of impingement members in the impingement cooling apparatus 300 may be integrally formed as a single component. That is, each of the subcomponents, e.g., the flanges 310, 311, the impingement member 302, the first protrusion 334, the second protrusion 335, the plurality of cross-supports 346, the standoffs 356, 358, and any other subcomponents of each row 320, 322 of the impingement member 302, may be manufactured together as a single body. In an exemplary embodiment, this may be done by utilizing the additive manufacturing system 1000 described herein. However, in other embodiments, other manufacturing techniques, such as casting or other suitable techniques, may be used. In this regard, utilizing additive manufacturing methods, each row 320, 322 of the impingement member 302 may be integrally formed as a single piece of continuous metal and, therefore, may include fewer subcomponents and / or joints compared to conventional designs. Integral formation of each row 320, 322 of impingement members 302 through additive manufacturing can advantageously improve the overall assembly process. For example, integral formation reduces the number of separate parts that must be assembled, thereby reducing the associated time and overall assembly costs. Additionally, it can advantageously reduce existing issues with, for example, leakage, joint quality between separate parts, and overall performance. In some embodiments (not shown), the entire impingement cooling apparatus 300 may be integrally formed as a single component. In such embodiments, the impingement cooling apparatus may have a single flange rather than the first flange 310 and second flange 311 from which all of the impingement members 302 extend.

[0093] FIG. 23 is a flowchart of a series of steps 2302-2306 defining a method 2300 of fabricating the impingement cooling apparatus 300 according to an embodiment of the present disclosure. The method 2300 can be performed using an additive manufacturing system, such as the additive manufacturing system 1000 described herein or another suitable system. As shown in FIG. 23 , the method 2300 includes step 2302 of irradiating a layer of powder in the powder bed 1120 to form a fused region. In many embodiments, the powder bed may be positioned on the build plate 1002 such that the fused region is fixedly attached to the build plate 1002, as shown in FIG. 15 . The method 2300 can include step 2304 of providing a subsequent layer of powder onto the powder bed 1120 from a first side of the powder bed 1120. The method 2300 further includes step 2306 of repeating steps 2302 and 2304 until the impingement cooling apparatus 300 is formed in the powder bed 1120.

[0094] FIG. 24 illustrates a perspective view of a cooling insert 400 isolated from other components of the integrated combustor nozzle 100 according to an embodiment of the present disclosure. As shown in FIG. 24 , the cooling insert 400 may extend between a first end 410 and a second end 412. In many embodiments, the cooling insert 400 includes a flange 414 that extends between and generally surrounds the walls 402, 403 at the first end 410 of the cooling insert 400. In many embodiments, the flange 414 may define one or more openings that provide fluid communication between the cooling insert 400, the high-pressure plenum 34, and / or one or more of the impingement panels 130 described herein. In various embodiments, the flange 414 may couple the cooling insert 400 to one of the inner liner segment 106 or the outer liner segment 108. As described in more detail below, the flange 414 may define both a first open end 418 and a second open end 428 to provide fluid communication between the high-pressure plenum 34 and the first and second walls of the cooling insert 400. In this manner, the first open end 418 and the second open end 428 defined in the flange 414 may function as high-pressure air inlets. In many embodiments, the cooling insert 400 may further include a low-pressure inlet 408 defined in the flange 414. As best shown in FIGS. 6 and 9 , the low-pressure inlet 408 may provide fluid communication between the collection duct 142 of the impingement panel 130 and the collection passage 406 of the cooling insert 400 ( FIG. 9 ).

[0095] FIG. 25 illustrates a cross-sectional view of a cooling insert 400 along an axial direction A, FIG. 26 illustrates a cross-sectional view along a radial direction R, and FIG. 27 illustrates a cross-sectional view of the cooling insert 400 along a circumferential direction C, in accordance with an embodiment of the present disclosure. As shown in FIG. 25 , the cooling insert 400 may include an axial centerline 401 extending between cooling insert walls 402, 403. In an exemplary embodiment, when the cooling insert 400 is installed in the integrated combustor nozzle 100, the axial centerline 401 may be aligned with the radial direction R of the gas turbine 10.

[0096] 25 , the cooling insert 400 may include a first wall 402 defining a first passageway 416 therein. As shown, the first wall 402 may extend generally radially from a first open end 418 defined in the flange 414 to a first closed end 420. In this manner, the first wall 402 may be a substantially hollow body that receives air from the high-pressure plenum 34 via the first open end 418 defined in the flange 414. In certain embodiments, the first wall 402 includes a first impingement side 422 spaced apart from a first solid side 424. As shown, the first passageway 416 may be defined directly between the first impingement side 422 and the first solid side 424. In various embodiments, the first impingement side 422 may define a first plurality of impingement openings 404 that may be configured to direct air from the first passage 416 toward a first sidewall (e.g., the pressure sidewall 116) of the combustion liner 110 ( FIG. 5 ). In many embodiments, the first plurality of impingement openings 404 may be sized and oriented to direct the pre-impingement air 152 in discrete jets to impinge on the inner surface 156 of the pressure sidewall 116. The discrete jets of air impinge on (or strike) the inner surface 156, forming a thin boundary layer of air above the inner surface 156 and enabling optimal heat transfer between the pressure sidewall 116 and the air.

[0097] Similarly, the cooling insert 400 may further include a second wall 403 spaced apart from the first wall 402. In many embodiments, the second wall 403 may define a second passageway 426 therein. As shown, the first wall 402 may extend generally radially from a second open end 428 defined in the flange 414 to a second closed end 430. In this manner, the second wall 403 may be a substantially hollow body that receives air from the high-pressure plenum 34 via the second open end 428 defined in the flange 414. In certain embodiments, the second wall 403 includes a second impingement side 432 spaced apart from a second solid side 434. As shown, the second passageway 426 may be defined directly between the second impingement side 432 and the second solid side 434. In various embodiments, the second impingement side 432 may define a second plurality of impingement openings 405 that may be configured to direct air from the second passage 426 toward a second sidewall (e.g., the suction side wall 118) of the combustion liner 110 ( FIG. 5 ). In many embodiments, the second plurality of impingement openings 405 may be sized and oriented to direct the pre-impingement air 152 in discrete jets to impinge on the inner surface 158 of the suction side wall 118. The discrete jets of air impinge on (or strike) the inner surface 158 ( FIG. 6 ), forming a thin boundary layer of air above the inner surface 158 and enabling optimal heat transfer between the suction side wall 118 and the air.

[0098] As used herein, the term "solid" can refer to a wall or walls that are impermeable so that air or other fluids cannot pass through. For example, the first solid side 424 and the second solid side 434 may have no impingement openings, holes, or voids that allow pre-impingement air 152 to escape to ensure that all air is directed toward the inner surfaces 156, 158 of the walls 116, 118 for cooling.

[0099] As shown in FIG. 25 , the first wall 402 may include a first row 436 of supports 438 extending between the first impingement side 422 and the first solid side 424. For example, in some embodiments, each support 438 may extend directly between the first impingement side 422 and the first solid side 424, thereby advantageously providing additional structural integrity to the first wall 402. As shown in FIG. 25 , each support 438 in the first row 436 of supports 438 may form an oblique angle 440 with the first solid side 424, which allows the supports 438 to be manufactured by the first wall 402 via an additive manufacturing system (such as the additive manufacturing system 1000 described herein). For example, in many embodiments, each support 438 in the first row 436 of supports 438 may form an oblique angle 440 with the first solid side wall 424 of between about 10° and about 80°. In other embodiments, each support 438 in the first row 436 of supports 438 may form an oblique angle 440 with the first solid sidewall 424 of between about 20° and about 70°. In certain embodiments, each support 438 in the first row 436 of supports 438 may form an oblique angle 440 with the first solid sidewall 424 of between about 30° and about 60°. In many embodiments, each support 438 in the first row 436 of supports 438 may form an oblique angle 440 with the first solid sidewall 424 of between about 40° and about 50°.

[0100] Similarly, the second wall 403 may include a second row 442 of supports 444 extending between the second impingement side 432 and the second solid side 434. For example, in some embodiments, each support 444 in the second row 442 of supports 444 may extend directly between the second impingement side 432 and the second solid side 434, thereby advantageously providing additional structural integrity to the second wall 403. As shown in FIG. 25 , each support 444 in the second row 442 of supports 444 may form an oblique angle 446 with the second solid side 434, thereby enabling the supports 444 to be manufactured by the second wall 403 via an additive manufacturing system (such as the additive manufacturing system 1000 described herein). For example, in many embodiments, each support 444 in the second row 442 of supports 444 may form an oblique angle 446 with the second solid side wall 434 of between about 10° and about 80°. In other embodiments, each support 444 in the second row 442 of supports 444 may form an oblique angle 446 with the second solid sidewall 434 of between about 20° and about 70°. In certain embodiments, each support 444 in the second row 442 of supports 444 may form an oblique angle 446 with the second solid sidewall 434 of between about 30° and about 60°. In many embodiments, each support 444 in the second row 442 of supports 444 may form an oblique angle 446 with the second solid sidewall 434 of between about 40° and about 50°.

[0101] The beveled angles 440, 446 of the supports 438, 444 allow the walls 402, 403 to be additively manufactured with minimal or no defects or distortion. For example, when additively manufactured layer by layer, such as using the additive manufacturing system 1000 described herein, the beveled angles 440, 446 of the supports 438, 444 advantageously prevent potentially harmful overhangs of the supports 438, 444, which could cause deformation and / or total collapse of the component. For example, supports extending vertically across an impingement member may be difficult and / or impossible to manufacture using an additive manufacturing system. Therefore, the beveled angles 440, 446 between the supports 438, 444 and the solid walls 424, 434 are favorable.

[0102] 26 , the first impingement side 422 may include a first contour that corresponds to a first wall, e.g., the pressure side wall 116. Similarly, in many embodiments, the second impingement side 422 may include a second contour that corresponds to a second wall, e.g., the suction side wall 116. In this manner, the impingement sides 422, 432 may each maintain a constant spacing from the respective sidewalls 116, 118 in the axial direction A, thereby optimizing impingement cooling. As used herein, contours that "correspond" to one another may refer to two or more walls or surfaces that each have matching or nearly identical curvatures in one or more directions.

[0103] In many embodiments, as shown in FIG. 26 , the first impingement side 422 may diverge away from the first solid wall 424 as it extends in the axial direction A. Similarly, the second impingement side 432 may diverge away from the second solid wall 434 as it extends in the axial direction A. More specifically, the first wall 402 may include a first parallel portion 448 and a first diverging portion 450. The first parallel portion 448 of the first wall 402 may be disposed proximate to the forward end of the cooling insert 400. As shown in FIG. 26 , at the first parallel portion 448, the first impingement side 422 may be generally parallel to the first solid side 424. The first diverging portion 450 of the first wall 402 may extend continuously from the first parallel portion 448. At the first diverging portion 450, the first impingement side 422 may gradually diverge away from the first solid wall 424 as it extends in the axial direction A, thereby gradually increasing the gap between the walls in the axial direction A. Similarly, the second wall 403 may include a second parallel portion 452 and a second diverging portion 454. The second parallel portion 452 of the second wall 403 may be disposed proximate to the forward end of the cooling insert 400. As shown in FIG. 26 , at the second parallel portion 452, the second impingement side 432 may be generally parallel to the second solid side 434. The second diverging portion 454 of the second wall 403 may extend continuously from the second parallel portion 452. In many embodiments, in the second branched portion 452, the second impingement side 432 can gradually branch away from the second solid wall 434 as it extends in the axial direction A, thereby gradually increasing the gap between the walls in the axial direction A.

[0104] In certain embodiments, a collection passage 406 may be defined between the first solid side 424 and the second solid side 434. For example, in many embodiments, the first solid side 424 and the second solid side 434 may be spaced apart from one another such that the collection passage 406 is defined therebetween. In many embodiments, the first solid side 424 and the second solid side 434 may each be a substantially flat plate extending parallel to one another in both the axial direction A and the radial direction R. The collection passage 406 may receive low-pressure air (relative to high-pressure pre-impingement air) from one or more sources and guide the low-pressure air to the fuel injectors 160, 161 for use in the secondary combustion zone 104. For example, the collection passage 406 may receive a first source of low-pressure air from one or more of the collection ducts 142 of the impingement panel 130 coupled to the cooling insert 400 via a low-pressure inlet 408 defined in the flange 414. Another source of low pressure air for the collection passage 406 may be post-impingement air 154 exiting the impingement side and impinging against the walls 116, 118, as shown in FIG.

[0105] As collectively shown in FIGS. 24-27 , one or more guide vanes 456 may extend between the first solid side 424 and the second solid side 434 to guide the low-pressure air toward the fuel injectors 160, 161. In various embodiments, each guide vane 456 may extend directly between the first solid side 424 and the second solid side 434, thereby coupling the first wall 402 of the cooling insert 400 to the second wall 403 of the cooling insert 400. In certain embodiments, the guide vanes 456 may be positioned within the collection passage 406 to allow the low-pressure air to travel along the guide vanes 456 toward the fuel injectors 160, 161. In many embodiments, each of the guide vanes 456 may include an arcuate portion 458 and a straight portion 460 that extend continuously from one another. The arcuate portion 458 may be positioned proximate the forward end of the cooling insert 400. A straight portion 460 of the guide vane 456 may extend from the arcuate portion 458 toward the aft end of the cooling insert 400. In many embodiments, the straight portion 460 of the guide vane may be generally parallel to the axial direction A when the cooling insert is installed in the integrated combustor nozzle 100.

[0106] 24-26 , the first impingement side may include a set of first standoffs 462 extending from the first impingement side 422 to a first sidewall (e.g., the pressure sidewall 116) when the cooling insert 400 is installed within the integrated combustor nozzle 100. Similarly, in many embodiments, the second impingement side may include a set of second standoffs 464 extending from the second impingement side 432 to a second sidewall (e.g., the suction sidewall 118). Each set of standoffs 462, 464 may function to maintain an appropriate spacing between the impingement side 422, 432 and one of the walls 116, 118 of the combustion liner 110. For example, in the exemplary embodiment, a standoff may extend from each respective impingement side and contact the wall 116, 118 of the combustion liner 110. For example, the standoffs 462, 464 are not bonded at both ends, but are integrally formed with the impingement sides 422, 432 at one end and contact the inner surface of either the pressure side wall 116 or the suction side wall 118 when the cooling insert 400 is installed in the combustion liner 110. In this manner, the standoffs 462, 464 may be removably coupled to the combustion liner 110. In the exemplary embodiment, the length of the standoffs 462, 464 may set the distance of the gap disposed between the impingement sides and the walls 116, 118 of the combustion liner 110.

[0107] 28 shows a close-up view of two oppositely disposed cooling inserts 400 according to an embodiment of the present disclosure. More specifically, FIG. 25 shows the closed ends 420 of the two oppositely disposed cooling inserts 400. In certain embodiments, each closed end 420 may include an arcuate portion 466 that curves around the cross-fire tube 122. In other embodiments (not shown) where the cross-fire tubes are not pre-set, the closed ends may extend straight (e.g., in the axial direction A).

[0108] In many embodiments, each of the cooling inserts 400 may be integrally formed as a single component. That is, each of the subcomponents, e.g., the first wall 402, the second wall 403, the flange 414, the guide vane 456, the standoffs 462, 464, and any other subcomponents of the cooling insert 400, may be manufactured together as a single body. In the exemplary embodiment, this can be done by utilizing the additive manufacturing system 1000 described herein. However, in other embodiments, other manufacturing techniques, such as casting or other suitable techniques, may be used. In this regard, utilizing additive manufacturing methods, the cooling insert 400 may be integrally formed as a single, continuous piece of metal and, therefore, may include fewer subcomponents and / or joints compared to conventional designs. The integral formation of the cooling insert 400 through additive manufacturing can advantageously improve the overall assembly process. For example, integral formation reduces the number of separate parts that must be assembled, thereby reducing the associated time and overall assembly costs. Additionally, existing issues with, for example, leakage, joint quality between separate parts, and overall performance may be advantageously reduced.

[0109] This written description uses examples to disclose the invention, including the best mode, and to enable any person skilled in the art to practice the invention, including making and using any devices or systems 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 contain structural elements that do not differ from the literal language of the claims, or equivalent structural elements that do not differ substantially from the literal language of the claims. [Explanation of symbols]

[0110] 10. Gas turbine 12 Entrance Section 14 Compressor Section 16 Combustion section, combustor 18 Turbine Section 20 Exhaust Section 22 Gas turbine shaft 24 Air 26 Compressed air 28 Fuel 30 Combustion Gas 32 Compressor discharge casing 34 High-Pressure Plenum 36 Annular Combustion System 38 Axial centerline 100 Integrated combustor nozzle, integrated combustion nozzle 102 Primary Combustion Zone 104 Secondary Combustion Zone 106 Inner liner segment 108 Outer liner segment 110 Combustion liner, combustion injection panel 112 Front end, upstream end 114 Rear end, downstream end part 116 first side wall, pressure side wall 117 Fuel injection module 118 second side wall, negative pressure side wall 120 Downstream turbine nozzle, integral turbine nozzle 122 Cross-fire tube 124 Air Cavity 126 Air Cavity 128 Ribs, bulkheads 129 Ribs, bulkheads 130 Outer impingement panel, impingement plate 131 Exterior, impingement panel 134 Inner impingement panel 135 External surface 136 Impingement plate, collection plate 138 Cooling Flow Gap 139 Impingement holes 140 Entrance section 141 Side wall 142 Collection duct 142' First collection duct 142'' Secondary collection duct 144 Premixed air plenum, collection passage 146 Radial inner wall 148 Radial outer wall 150 side wall 152 Pre-impingement Air 154 Post-impingement air, spent cooling air 156 Inside 158 Inside 160 Positive pressure side fuel injector 161 Vacuum side fuel injector 162 Entrance 164 positive pressure side injection outlet 165 Negative pressure side injection outlet 166 Entrance 168 frames 172 Gap 174 Collection Passage 176 First Width 178 Second Width 180 Connecting Duct 182 Impingement panel segment, panel section 184 anterior segment 185 Middle Segment 186 posterior segment 188 elongated slot opening 190 Front end 192 Rear end 194 Support 196 First End 197 First Aspect 198 Second End 199 Second Aspect 200 angle 202 Angle 206 Center axis 208 First End 210 second end 211 End Plate 212 flange 213 Connection Surface 300 Impingement Cooling Device 302 Impingement member, impingement cooling member 304 Impingement opening 306 First End 308 Second End 310 First flange, combustion liner 311 Second flange 312 closed end 313 Opening, open end 314 Impingement Wall 316 Solid Wall 318 Camber Axis 320 First Column 322 Second Column 324 Rear end 326 front end 328 First solid sidewall 330 Second solid side wall 332 internal volume 334 First protrusion 335 Second protrusion 336 Axial Centerline 338 Inside 340 Inside 342 First Part 344 Second Part 346 Cross Support 348 First Support Bar 350 Second Support Bar 352 intersection 354 angle 356 Sidewall Standoff 358 Impingement wall standoff, side wall standoff 360 length 400 Cooling Insert, Impingement Air Insert 401 Axial centerline 402 The First Wall 403 The Second Wall 404 first plurality of impingement openings 405 second plurality of impingement openings 406 Collection Passage 408 Low pressure inlet 410 first end 412 Second End 414 flange 416 First Passage 418 First open end 420 First closed end 422 First Impingement Side 424 first solid side, first solid side wall 426 Second Passage 428 Second Open End 430 Second closed end 432 Second Impingement Side 434 Second solid side, second solid side wall 436 First Column 438 Support 440 Bevel 442 Second Column 444 Support 446 Bevel 448 First parallel section 450 First branch 452 Second parallel section 454 Second branch 456 Guide Vane 458 Arcuate part 460 Straight section 462 First Standoff 464 Second Standoff 466 Arcuate part 1000 Additive Manufacturing Systems 1002 Build Plate 1120 Powder bed 1160 Recoater Arm 1180 Powder Level 1200 Laser 1220 Object 1260 reservoir 1280 Waste container 1320 Galvo Scanner 1360 Energy Beam 1600 methods 2300 methods A axis direction C Circumferential direction R radius direction T transverse direction

Claims

1. An impingement panel (130, 134) configured to provide impingement cooling to an exterior surface (131, 135), comprising: an impingement plate (136) disposed along the outer surface (131, 135), the impingement plate (136) defining a plurality of impingement openings (139) that direct coolant toward the outer surface (131, 135) in discrete jets; a collection duct (142) spaced from the impingement plate (136) and defining a collection passage (144); an inlet portion (140) extending from said impingement plate (136) to said collection duct (142); at least one support (194) coupled to the impingement plate (136) and at least one of the inlet portion (140) and the collection duct (142), the at least one support (194) extending between and coupled to the inlet portion (140), the collection duct (142), and the impingement plate (136); An impingement panel (130, 134).

2. 2. The impingement panel (130, 134) of claim 1, wherein the at least one support (194) extends from a first end (196) fixedly coupled to the impingement plate (136) to a second end (198) fixedly coupled to the collection duct (142).

3. 3. The impingement panel (130, 134) of claim 2, wherein the at least one support (194) includes a first side (197) and a second side (199) extending between the first end (196) and the second end (198), the first side (197) being fixedly coupled to the inlet portion (140).

4. The impingement panel (130, 134) of claim 3, wherein the second side (199) of the at least one support (194) forms an angle (200) with the impingement plate (136) of between about 10 degrees and about 75 degrees.

5. The impingement panel (130, 134) of any preceding claim, wherein the at least one support (194) forms an angle (202) with the inlet portion (140) of between about 10 degrees and about 90 degrees.

6. The impingement panel (130, 134) of claim 1, wherein the impingement panel (130, 134) comprises a plurality of impingement panel (130, 134) segments (182) coupled together.

7. 7. The impingement panel of claim 6, wherein each impingement panel segment of the plurality of impingement panel segments extends between a first end of the impingement panel segment and a second end of the impingement panel segment, the first end including a flange extending from the impingement plate of the impingement panel segment, the flange being integrally formed with the impingement panel segment.

8. 8. The impingement panel (130, 134) of claim 7, wherein an end plate (211) is fixedly coupled to the second end (198) of at least one impingement panel (130, 134) segment (182) of the plurality of impingement panel (130, 134) segments (182), the end plate (211) coupling the second end (198) of the at least one impingement panel (130, 134) segment (182) to a respective flange (212) of an adjacent impingement panel (130, 134) segment (182).

9. A method (1600) for fabricating an impingement panel (130, 134), comprising: (a) irradiating (1602) a powder layer in a powder bed (1120) to form a fused region, the powder bed (1120) being disposed on a build plate (1002); (b) providing (1604) a subsequent layer of powder onto the powder bed (1120) by passing a recoater arm (1160) over the powder bed (1120) from a first side (197) of the powder bed (1120); (c) repeating steps (a) and (b) (1606) until the impingement panel (130, 134) is formed on the build plate (1002), the impingement panel (130, 134) comprising: an impingement plate (136) defining a plurality of impingement openings (139); a collection duct (142) spaced from the impingement plate (136) and defining a collection passage (144); an inlet portion (140) extending from said impingement plate (136) to said collection duct (142); at least one support (194) coupled to the impingement plate (136) and at least one of the inlet portion (140) and the collection duct (142); Equipped with Method (1600).

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