Aerodynamic Combustor Panel Curvature for Low-Stress Shell Assembly
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Solution Overview
Problem
In gas turbine engine assembly, combustor panels often misalign with shells due to inadequate dimensional accuracy checks, leading to pre-loads and strain that result in early coating spallation and reduced engine life.
Innovation Solution
The aerodynamic component is formed with an initial shape that deviates from the shell shape, allowing for deformation during assembly to achieve a precise fit, utilizing casting and deformation processes such as cold working and electron-beam physical vapor deposition (EBPVD) to ensure a final shape that matches the shell's curvature, thereby improving sealing and reducing residual stress.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If combustor panels are manufactured with standard dimensional accuracy checks only prior to coating, then manufacturing process is simple and fast, but dimensional accuracy deteriorates after coating and laser drilling, leading to misalignment with shells
Solution Approach 1:
The patent applies preliminary action by performing dimensional checks at multiple stages before final assembly, specifically after coating and after laser drilling operations. This ensures that any dimensional deviations are detected and corrected early in the manufacturing process, preventing misalignment issues at assembly while maintaining a manageable manufacturing process through systematic checkpoint implementation
2Reliability
If combustor panels are manufactured with standard processes, then manufacturing cost and time are reduced, but misalignment with shells occurs, causing pre-loads and strain that reduce combustor life
Solution Approach 1:
The patent implements preliminary action by conducting dimensional verification at multiple critical stages during manufacturing (after coating, after laser drilling) and performing pre-fit checks before final assembly. This proactive approach ensures panels are dimensionally accurate before commitment to assembly, preventing misalignment-induced stress and extending combustor life without requiring time-consuming rework or adjustments during final assembly
Solution Approach 2:
The patent applies feedback by using dimensional measurement data from coating and laser drilling stages to determine whether rework or adjustment is needed before final assembly. This feedback loop ensures that any dimensional deviations are identified and corrected based on actual measurements, maintaining high reliability while avoiding unnecessary time loss through targeted rather than universal rework
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 enhances the fitting accuracy of combustor panels, reduces premature coating spallation, and extends the lifespan of the combustor by ensuring a precise, spring-like fit that maintains sealing effectiveness and reduces stress.
Implementation Method 1
deformed to have a substantially uniform radius of curvature similar to the substantially uniform radius of curvature of the shell
Implementation Method 2
electron-beam physical vapor deposition (EBPVD)
Data Source
AI summary
An aerodynamic component of a gas turbine engine is provided and is fittable to a shell having a shell shape. The aerodynamic component includes a body having a component shape initially deviating from the shell shape prior to an assembly operation in which the aerodynamic component is to be fit to the shell. Deviation of the component shape from the shell shape aids in an establishment of a final desired shape of the aerodynamic component following the assembly operation.