Axial-radial swirler design and manufacturing method for a combustion chamber

Abstract

The invention relates to an axial-radial swirler design and manufacturing method for a combustion chamber. The swirler increases flow homogeneity by combining axial and radial channels, optimizes temperature distribution, and renders the flame shape symmetric. By being manufactured using an additive manufacturing method, high repeatability and a low manufacturing defect rate are achieved.

Description

[0001] SPECIFICATION

[0002] AXIAL-RADIAL SWIRLER DESIGN AND MANUFACTURING METHOD FOR A COMBUSTION CHAMBER

[0003] Technical Field

[0004] The invention relates to thermal energy systems, combustion technologies, and engine design solutions.

[0005] In particular, the invention relates to combustion chamber design and fluid dynamics. Furthermore, since the invention provides advantages through the use of additive manufacturing technologies, it also relates to manufacturing technologies and production processes.

[0006] Background of the Art

[0007] In the prior art, various combustion chamber swirler designs have been developed in order to optimize the combustion process, provide improved flame stability, and minimize undesirable effects such as temperature gradients, turbulence losses, or non-uniform flow. Among these designs, inclined, curved, or variable cross-section channels are employed to improve flow direction and homogenization. Such channel designs contribute to a more efficient combustion process by enabling the swirlers to optimize fluid velocity, direction, and turbulence level.

[0008] Another design solution known in the prior art involves airfoil profile modifications. In this approach, blades having asymmetric profiles or different curvatures are designed in order to stabilize the flow by modifying the aerodynamic characteristics of the swirler blades. These designs aim to achieve a more balanced and effective combustion process by optimizing fuelair mixture ratios, particularly in the flame-holding region.

[0009] The use of different materials and manufacturing methods in order to increase the durability of the swirlers and facilitate manufacturing processes is also among the solutions in the prior art. However, such methods generally require complex manufacturing processes and may cause difficulties in terms of repeatability.

[0010] Computational fluid dynamics (CFD) analyses are another solution method frequently used in current technology. This approach enables detailed analysis and optimization of flowcharacteristics in swirler designs. However, such analyses are primarily focused on improving the performance of existing swirler designs and are directed toward enhancing existing structures rather than proposing a new configuration.

[0011] Nevertheless, the existing art is generally limited to axial or radial swirlers. Solutions that combine the advantages of these two structural types or propose an alternative structure have not been sufficiently addressed in the prior art, or their applicability has remained limited.

[0012] In view of the deficiencies present in existing applications of the prior art, and since the existing solutions fail to address problems such as requiring complex manufacturing processes, causing difficulties in terms of repeatability, and having limited applicability, it has become necessary to develop improved axial-radial swirler design and manufacturing solutions, particularly for combustion chambers.

[0013] Brief Description of the Invention

[0014] The invention aims to present a structure having different technical features that introduces a new approach in this field, unlike the configurations used in the prior art.

[0015] A primary object of the invention is to obtain a more homogeneous swirler flow by converting a swirler having axial channel structures into an axial-radial configuration, without resorting to complex manufacturing methods and without employing complex channel geometries.

[0016] Another object of the invention is to achieve a more symmetric flame shape and thereby ensure a homogeneous temperature distribution, owing to the homogeneous flow generated by the axial-radial swirler.

[0017] Another object of the invention is to reduce hot spots on combustion chamber walls and to bring combustion chamber outlet temperature profile values to a more desired level by means of the homogeneous temperature distribution provided.

[0018] Another object of the invention is to enable a manufacturing process that allows faster production, fewer manufacturing defects, and high repeatability by means of additive manufacturing, owing to the axial-radial configuration of the swirler.Brief Description of the Drawings

[0019] In order to best understand the configuration of the present invention and its advantages together with additional elements, reference should be made to the drawings described below.

[0020] Figure 1: A perspective view of the axial-radial swirler design for a combustion chamber according to the invention.

[0021] Figure 2: A perspective view of the axial-radial swirler design for a combustion chamber according to the invention.

[0022] Reference Numerals

[0023] 1. Radial channel

[0024] 2. Primary axial channel

[0025] 3. Secondary axial channel

[0026] 4. Axial swirler outlet

[0027] 5. Injector cavity

[0028] 6. Radial swirler outlet

[0029] Detailed Description of the Invention

[0030] In this detailed description, preferred embodiments of the invention are disclosed solely for the purpose of better understanding the subject matter and without creating any limiting effect.

[0031] The axial-radial swirler design and manufacturing method for a combustion chamber according to the invention comprises the steps of

[0032] • providing primary and secondary axial channels (2, 3) in a specific portion of the swirler to establish an axial flow structure,

[0033] • combining a portion of said axial channels with radial channels (1),

[0034] • discharging the air passing through the radial channels (1) through a radial swirler outlet (6), and discharging the air passing through the primary and secondary axial channels (2, 3) through axial swirler outlets (4),

[0035] • enabling the air entering the swirler to be distributed more uniformly and to enter the combustion chamber, due to the length-to-diameter ratio of the radial channels (1) beinggreater than that of the primary and secondary axial channels (2, 3), thereby reducing airflow irregularities,

[0036] • enabling the air exiting the axial swirler outlet (4), in which irregularities are reduced, to mix more uniformly with the fuel discharged from a fuel injector positioned in the injector cavity (5), thereby rendering the flame shape more symmetric,

[0037] • minimizing the formation of hot spots on combustion chamber walls and optimizing temperature distribution by reducing irregularities in the flow and in the flame,

[0038] • manufacturing the entire structure by an additive manufacturing method using powder materials consisting of superalloys,

[0039] • ensuring high repeatability and reducing manufacturing defects due to a geometry suitable for additive manufacturing,

[0040] • obtaining consistency in flow test results among specimens produced by additive manufacturing.

[0041] Coking refers to the solidification and accumulation of fuel at the injector tip, resulting in clogging of the injector and loss of functionality. This condition is prevented by the primary axial channel (2). Atomization refers to converting liquid fuel into small particles to render it suitable for ignition. The injector performs this function, and the secondary axial channel (3) assists the atomization process.

[0042] The channel in which fuel and air are mixed is the axial swirler outlet (4). The region in which the injector is positioned is the injector cavity (5). The opening through which the air passing through the radial channel (1) enters the combustion chamber is the radial swirler outlet (6). One of the prominent innovations of the invention is the inclusion of at least one radial channel (1) configured to provide flame holding. By means of this radial channel, stable flame extinction is prevented. Radial channels exhibit improved flame-holding capability compared to axial channels due to their aerodynamic performance. In particular, radial channels impart a stronger angular momentum to the airflow than axial channels, thereby forming a more stable flameholding region.

Claims

CLAIMS1. An axial -radial swirler design and manufacturing method for a combustion chamber, characterized in that it comprises the steps of:o connecting a portion of a primary axial channel (2) and a secondary axial channel (3) with radial channels (1),o discharging the air passing through the radial channels (1) through a radial swirler outlet (6), and discharging the air passing through the primary axial channel (2) and the secondary axial channel (3) through axial swirler outlets (4), o enabling the air entering the swirler to be distributed more uniformly and to enter the combustion chamber due to the length-to-diameter ratio of the radial channels (1) being greater than that of the primary and secondary axial channels (2, 3), thereby reducing airflow irregularities,o enabling the air exiting the axial swirler outlet (4), in which irregularities are reduced, to mix more uniformly with the fuel discharged from a fuel injector positioned in an injector cavity (5), thereby rendering the flame shape more symmetric,o minimizing the formation of hot spots on combustion chamber walls and optimizing temperature distribution by reducing irregularities in the flow and in the flame.

2. The axial-radial swirler design and manufacturing method according to claim 1, characterized in that the swirler is manufactured by an additive manufacturing method using powder materials consisting of superalloys.

3. The axial-radial swirler design and manufacturing method according to claim 1, characterized in that high repeatability is ensured and manufacturing defects are reduced due to a geometry suitable for additive manufacturing.

4. The axial-radial swirler design and manufacturing method according to claim 1, characterized in that consistency in flow test results is obtained among specimens produced by additive manufacturing. An axial-radial swirler, comprising:

5. An axial-radial swirler, comprising:o a primary axial channel (2) configured to prevent coking,o a secondary axial channel (3) configured to assist atomization,o an axial swirler outlet (4) constituting a channel in which fuel and air are mixed, o an injector cavity (5) in which an injector is positioned,o a radial swirler outlet (6) through which air passing through a radial channel (1) enters the combustion chamber,characterized in that it comprises at least one radial channel (1) configured to provide flame holding.

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