Additive Flame Tube Structure With Double-Wall End-Wall Cooling
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Solution Overview
Problem
Conventional manufacturing processes for flame tubes in turbomachines are lengthy, expensive, and difficult to modify, with significant thermal stresses on the end wall that can lead to premature damage.
Innovation Solution
A method using additive manufacturing to produce a flame tube as a single piece with a double wall and air cooling channel, connected by bridges that ensure mechanical strength and calibrate the passage section, reducing the need for extensive machining and assembly steps.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If conventional stamping and assembly processes are used to manufacture flame tubes, then the manufacturing process is well-established and parts can be produced using traditional methods, but the process is lengthy, expensive, and difficult to modify when geometry changes are needed
Solution Approach 1:
The patent merges multiple separate stamped parts into a single monolithic flame tube structure manufactured by additive manufacturing. This integration eliminates the need for multiple stamping operations, assembly steps, and associated tooling, thereby reducing manufacturing time and enabling easier geometric modifications without requiring multiple tooling changes.
Solution Approach 2:
The patent replaces traditional mechanical stamping and assembly processes with additive manufacturing technology. This substitution eliminates the need for stamping dies and mechanical assembly operations, significantly reducing manufacturing time and providing greater design flexibility for geometry modifications.
2Ease of manufacture
If conventional stamping and assembly processes are used to manufacture flame tubes, then existing manufacturing infrastructure can be utilized, but the process is expensive and complex with numerous machining and assembly steps
Solution Approach 1:
The patent combines multiple manufacturing operations (stamping, machining, assembly) into a single additive manufacturing process. This consolidation reduces process complexity by eliminating intermediate steps and tooling requirements while maintaining manufacturability through digital design and direct fabrication.
Solution Approach 2:
The patent replaces complex mechanical stamping and assembly systems with additive manufacturing technology. This substitution simplifies the overall manufacturing process by eliminating the need for multiple machines, tooling setups, and assembly operations, thereby reducing process complexity while preserving ease of manufacture.
3Strength
If the end wall is designed with high strength to withstand thermal stresses, then the flame tube can resist thermal loads, but the thermal stresses cause premature damage and deterioration of the end wall
Solution Approach 1:
The patent introduces a cooling air flow system that channels cooling air through the end wall structure. This pneumatic cooling system removes thermal energy from the end wall, reducing thermal stresses and preventing premature damage while maintaining the structural strength required to withstand thermal loads.
Solution Approach 2:
The patent changes the thermal parameter of the end wall by introducing active cooling. This parameter change reduces the operating temperature and thermal stress levels in the end wall, thereby extending service life while preserving mechanical strength through the cooling effect.
4Productivity
If the flame tube is manufactured as a single piece by additive manufacturing, then the structure can be produced without extensive machining and assembly, but the complex internal geometry with cooling channels requires advanced manufacturing capabilities
Solution Approach 1:
The patent replaces traditional mechanical manufacturing methods (stamping, machining, assembly) with additive manufacturing technology. This substitution enables the production of complex single-piece structures with internal cooling channels that would be impossible or extremely difficult to manufacture using conventional methods, thereby improving productivity while managing manufacturing capability requirements.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach allows for the production of a complex flame tube structure in a single piece, reducing costs and thermal stress on the end wall, while enhancing mechanical strength and manufacturability, thus addressing the limitations of conventional methods.
Implementation Method 1
a first layer of powder of a metal, a metal alloy or ceramic of controlled thickness is deposited on a manufacturing plate, then a step consisting of heating with a heating means (a laser beam or an electron beam) a predefined area of the powder layer
Implementation Method 2
The flame tube can be made by sintering or selective melting of powder, for example using a laser beam or an electron beam
Implementation Method 3
a first layer of powder of a metal, a metal alloy or ceramic of controlled thickness is deposited on a manufacturing plate, then a step consisting of heating with a heating means (a laser beam or an electron beam) a predefined area of the powder layer
Implementation Method 4
The flame tube can be made by sintering or selective melting of powder, for example using a laser beam or an electron beam
Implementation Method 5
at least a portion of said end wall forming a double wall comprising a first portion and a second portion connected to each other and spaced apart from each other so as to delimit a flow channel for a cooling air flow opening into said internal volume
Data Source
Figure 1~2
Figure 3~4
Figure 5~6
AI summary
The invention relates to a method for manufacturing a flame tube (1) for a turbomachine, the flame tube (1) extending around an axis (X) and comprising a radially inner annular wall (2) and a radially outer annular wall (3), connected to one another by an end wall (4) or head wall, the inner wall (2), the outer wall (3) and the end wall (4) defining an internal space (5), at least one portion of said end wall (4) forming a double wall (6) comprising a first portion (7) and a second portion (8) connected to one another and spaced apart from one another so as to define a flow channel (9) for a cooling air flow opening into said internal space (5), the flow channel (9) comprising at least one air inlet opening (13), the first and second portions (7, 8) of the double wall (6) being connected by connecting areas or bridges (10) extending into the flow channel of the cooling air stream (9), the flame tube (1) being produced by additive manufacturing.