AM Combustion Liner With Axial Fuel Injector to Cut Assembly Complexity
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Solution Overview
Problem
Current gas turbine combustors require numerous separately manufactured parts that need to be assembled, leading to complex and time-consuming processes, which can take weeks to complete.
Innovation Solution
An additively manufactured combustor body is created as a one-piece member comprising a combustion liner, tapered transition portion, axial fuel stage injectors, and an aft frame, with integrated fuel and cooling passages, reducing the number of parts and assembly steps.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If traditional separate manufacturing and assembly processes are used for combustor parts, then manufacturing flexibility and part replaceability are maintained, but manufacturing time increases significantly and assembly complexity increases
Solution Approach 1:
The patent combines multiple separate combustor components (combustion liner, flow sleeve, tapered transition portion, axial fuel stage injector) into a single additively manufactured combustor body. This integration eliminates the need for separate manufacturing and assembly of these parts, directly reducing manufacturing time and assembly complexity while maintaining functional performance.
2Ease of manufacture
If multiple separate parts are assembled to form the combustor, then manufacturing adaptability is maintained, but the number of parts and assembly steps increase
Solution Approach 1:
The patent merges multiple discrete parts into a single monolithic combustor body produced by additive manufacturing. This reduces the number of parts from multiple separate components to one integrated structure, thereby reducing assembly steps while the additive manufacturing process itself provides manufacturing adaptability through digital model modifications.
3Reliability
If traditional manufacturing methods with multiple parts are used, then design flexibility is maintained, but welds and joints increase leading to reduced durability and increased leakage
Solution Approach 1:
The patent integrates multiple components into a single additively manufactured part, eliminating welds and mechanical joints between the combustion liner, flow sleeve, tapered transition portion, and axial fuel stage injector. This monolithic structure removes potential failure points from welding and assembly, thereby improving durability and reducing leakage risks.
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 results in a 70% reduction in parts, improved durability by eliminating welds, and reduced leakages, while enabling quick manufacturing updates and maintaining desired pressure ratios.
Implementation Method 1
Additive manufacturing such as direct metal laser melting (DMLM) or selective laser melting (SLM) has emerged as a reliable manufacturing method
Implementation Method 2
the AM combustor body includes a plurality of parallel, sintered metal layers
Data Source
AI summary
A combustor for a gas turbine system includes an additively manufactured (AM) combustor body including a one-piece member. The member includes a combustion liner including a cylindrical portion and a tapered transition portion at an aft end of the cylindrical portion; and at least one axial fuel stage (AFS) injector directed into the combustion liner. The member may also include at least one flow sleeve surrounding at least part of the combustion liner; and an aft frame at the aft end of the transition portion. The AM combustor body includes a plurality of parallel, sintered metal layers. A method of manufacturing such a combustor body is also provided.