Combustor Heat Shield With Integrated Louver
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Solution Overview
Problem
The existing manufacturing methods for combustor heat shields are inefficient due to the need for complex secondary shaping operations and high tooling costs, particularly when incorporating film cooling louvers, as casting operations struggle with tight tolerances and frequent tool wear.
Innovation Solution
The method involves metal injection molding of a green heat shield body and louver, positioning them to form an air cooling gap, and co-sintering them at a sufficient temperature to fuse them into a one-piece component, eliminating the need for drilling and secondary shaping operations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If casting operations are used to manufacture heat shields, then high temperature resistance is achieved, but tight tolerances and complex secondary shaping operations are required
Solution Approach 1:
The patent combines the heat shield and louver into a single integrated component manufactured through investment casting. This merging eliminates the need for separate casting operations and subsequent assembly, achieving tight tolerances throughout the entire structure including the louver interface without requiring secondary shaping operations.
Solution Approach 2:
The integrated heat shield design segments the cooling function into an integrated louver structure rather than requiring separate cooling components. The louver is formed as an integral part of the heat shield, allowing precise positioning and tight tolerances to be achieved during the single casting process.
2Adaptability or versatility
If secondary shaping operations like drilling are performed on cast heat shields, then film cooling louvers can be incorporated, but tooling costs increase due to frequent tool wear
Solution Approach 1:
The louver structure is preliminarily formed during the investment casting process itself, before any secondary operations. The intricate louver geometry and precise positioning are created in the initial casting, eliminating the need for subsequent drilling or machining operations that would require expensive tooling and frequent tool replacement.
Solution Approach 2:
By combining the louver creation with the heat shield manufacturing in a single investment casting operation, the patent eliminates separate secondary shaping operations. This integration removes the source of tool wear and associated costs entirely, as no drilling or machining tools are needed.
3Ease of manufacture
If separate components are used for heat shield and louver, then manufacturing flexibility is maintained, but assembly complexity and alignment precision increase
Solution Approach 1:
The patent merges the heat shield and louver into a single monolithic component created through investment casting. This eliminates all assembly operations and alignment requirements, as there is only one component to manufacture. The precise spatial relationship between the louver and heat shield surfaces is achieved through the casting process itself, not through post-manufacturing assembly.
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 seamless, cost-effective combustor dome heat shield assembly with improved cooling efficiency and reduced tooling costs, enabling precise integration of film cooling louvers without the need for additional alignment structures.
Implementation Method 1
co-sintering said green heat shield body and said green cooling louver at a temperature sufficient to fuse them together into a one-piece component
Data Source
AI summary
A combustor dome heat shield and a louver are separately metal injection molded and then fused together to form a one-piece combustor heat shield.