Turbomachine Combustor Aperture Reinforcement via Broaching

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Solution Overview

Problem

Conventional combustor apertures in turbomachine combustors face failure due to high temperature gradients and challenging welding access, leading to material degradation and bonding issues.

Innovation Solution

The method involves broaching existing apertures to form modified profiles with increased surface area, which are then fillet welded to a combustor ring for enhanced bonding and reinforcement, using a broaching tip with specific surfaces to create a smooth, protruding interface.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If a reinforcing sleeve is applied to the aperture and welded in place, then the aperture is reinforced, but the high temperature gradient causes the sleeve to fail

Engineering Contradiction:

Improveaperture reinforcementVSAvoidsleeve failure due to temperature gradient

Core Design Contradiction:

StrengthVSReliability

Solution Approach 1:

The invention changes the geometric parameters of the aperture by forming a protruding profile that extends into the combustion chamber. This profile modification alters the thermal and structural parameters, distributing temperature gradients more effectively and reducing thermal stress on the aperture edges, thereby preventing sleeve failure while maintaining reinforcement.

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The invention transitions from a two-dimensional planar aperture to a three-dimensional structure by forming a protruding profile that extends radially into the combustion chamber. This dimensional change creates additional surface area for heat dissipation and structural support, resolving the temperature gradient issue while providing reinforcement.

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

2Strength

If a reinforcing sleeve is applied to the aperture, then the aperture is reinforced, but welding the sleeve effectively is difficult due to limited access

Engineering Contradiction:

Improveaperture reinforcementVSAvoidwelding difficulty

Core Design Contradiction:

StrengthVSEase of manufacture

Solution Approach 1:

Instead of adding a sleeve from the outside and welding it to the aperture edge, the invention inverts the approach by forming the reinforcement profile directly within the aperture from the inside. This inversion eliminates the need for external welding operations, making the manufacturing process significantly easier and more accessible.

Inventive Principle:

Principle #13The other way round (Inversion)

Solution Approach 2:

The invention extracts the welding operation from the manufacturing process entirely by forming the protruding profile through machining or forming operations on the aperture itself. This eliminates the complex welding step that was previously required to attach reinforcing sleeves, simplifying manufacturing.

Inventive Principle:

Principle #2Taking out (Extraction)

3Strength

If the aperture profile is modified to protrude radially outward, then bonding between the aperture and combustor ring is enhanced, but the manufacturing process becomes more complex

Engineering Contradiction:

Improvebonding between aperture and combustor ringVSAvoidbroaching process complexity

Core Design Contradiction:

StrengthVSDevice complexity

Solution Approach 1:

The protruding profile is formed as a preliminary action during aperture fabrication, before the combustor ring is installed. By pre-forming the reinforcement geometry through broaching or machining, the complex shaping operation is performed when the aperture is accessible and isolated, simplifying the overall manufacturing sequence despite the complexity of the profile itself.

Inventive Principle:

Principle #10Preliminary action

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 strengthens the apertures, enhances bonding between the apertures and the combustor ring, and improves resistance to cracking and fatigue, while facilitating effective welding.

Implementation Method 1

broaching the existing aperture in the turbomachine combustor to modify an initial profile of the existing aperture in the turbomachine combustor and form a modified profile

Methodology Applied

Scientific EffectMachining:

Implementation Method 2

welding the existing aperture to a combustor ring, wherein the modified profile enhances bonding between the existing aperture and the combustor ring

Methodology Applied

Scientific EffectWelding: Welding

Data Source

PatentUS9377199B2Methods of reinforcing combustor aperture and related combustor

Publication Date: 2016.06.28 GE INFRASTRUCTURE TECH LLC

AI summary

Various embodiments include methods of reinforcing apertures in turbomachine combustors, and related combustors. In various particular embodiments, a method of reinforcing an existing turbomachine combustor aperture includes: broaching the existing aperture to modify an initial profile of the existing aperture and form a modified profile, where the modified profile protrudes radially outwardly from an outer surface of the turbomachine combustor; and welding a combustor ring along an inner surface of the modified profile, where the modified profile enhances bonding between the existing aperture and the combustor ring.