AM Combustor Aft Frame Replacement for Weld-Limited Lifespan
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Solution Overview
Problem
Current combustors in gas turbine systems have numerous parts that need welding, leading to life-limiting structures such as welds and high stress geometries, which reduce their lifespan, and additive manufacturing techniques are limited by build platform size and time, making large-scale replacement challenging.
Innovation Solution
An additively manufactured part is used to replace the aft section of a tapered transition portion and aft frame in the combustor, incorporating sintered metal layers and improved materials to eliminate life-limiting structures and enhance durability, while allowing for integration with existing components through a receiving element and welding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional welding methods are used to assemble combustor parts, then assembly is straightforward, but life-limiting structures reduce lifespan
Solution Approach 1:
The patent combines multiple separate combustor parts (tapered transition portion and aft frame) into a single additively manufactured component. This integration eliminates the weld joint between these parts, removing a life-limiting structure while maintaining the functional assembly through monolithic construction.
Solution Approach 2:
The patent segments the replacement strategy by selectively additively manufacturing only the aft section containing life-limiting structures, while retaining the forward section as the original component. This partial replacement approach targets specific problematic areas without requiring complete assembly disassembly.
2Reliability
If additive manufacturing is used for large combustor parts, then life-limiting structures are eliminated, but build platform size limits part dimensions
Solution Approach 1:
The patent divides the combustor into segments that can be selectively manufactured. The aft section with life-limiting structures is additively manufactured separately, while the forward section remains as the original component. This segmentation allows additive manufacturing to be applied to the specific problematic region without requiring the entire combustor to fit within build platform constraints.
Solution Approach 2:
The patent introduces a receiving element as an intermediary feature that connects the additively manufactured aft section to the forward section. This receiving element enables integration between the new and existing components, allowing the system to benefit from additive manufacturing where needed while maintaining compatibility with traditional assembly methods.
3Device complexity
If additive manufacturing is used for large combustor parts, then part integration is improved, but build time increases
Solution Approach 1:
The patent segments the manufacturing process by applying additive manufacturing only to the aft section that contains life-limiting structures, rather than manufacturing the entire combustor. This selective approach reduces build time while still achieving the integration benefits in the critical region where multiple parts were previously joined.
Solution Approach 2:
The patent applies additive manufacturing partially - only to the extent necessary to eliminate life-limiting structures in the aft section. This partial action approach achieves the reliability improvement without incurring the full time cost of additively manufacturing the entire combustor assembly.
4Ease of manufacture
If individual parts are replaced traditionally, then replacement is simple, but manufacturing costs remain high
Solution Approach 1:
The patent merges multiple replacement operations into a single additive manufacturing process. By combining the tapered transition portion and aft frame into one monolithic component manufactured in a single build, the process eliminates the need for separate manufacturing and assembly operations for each part, reducing overall manufacturing complexity and material waste.
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
The solution extends the lifespan of the combustor by eliminating life-limiting structures, improving material quality, and reducing manufacturing costs, while maintaining operational efficiency and compatibility with existing systems.
Implementation Method 1
the replacement AM part including a receiving element configured to receive part of the remaining non-AM part of the combustor body and a plurality of parallel, sintered metal layers
Data Source
AI summary
A combustor for a gas turbine (GT) system includes a combustor body including a non-additively manufactured (non-AM) part having corrosion at a first level and a replacement additively manufactured (AM) part coupled to the non-AM part. The replacement AM part has corrosion at a second level less than the first level. The replacement AM part includes at least an aft section of a tapered transition portion and an aft frame of the combustor body, and a plurality of shared parallel, sintered metal layers extending into the aft section of the tapered transition portion and the aft frame. The replacement AM part may also include a receiving element in a forwardmost end thereof configured to receive a rearwardmost remaining end of the non-AM part. The replacement AM part may also optionally include an AFS injector mount and part of a cylindrical portion of a combustion liner.