Additive Manufactured Combustor Wall Cooling Channels
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Solution Overview
Problem
Gas turbine engine combustor walls face durability issues due to thermal mechanical fatigue and mechanical loads, leading to cracking and the need for frequent replacement.
Innovation Solution
A cooled wall design for gas turbine engine combustors featuring an annular outer wall, inner wall segments, and connecting walls forming a monolithic body through additive manufacturing, with a functionally graded distribution of materials for enhanced durability and thermal management.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If conventional cooling schemes are used in combustor walls, then thermal protection is provided, but thermal mechanical fatigue causes cracking and reduced durability
Solution Approach 1:
The patent implements different material compositions at different locations within the combustor wall structure. The functionally graded material distribution provides varying thermal and mechanical properties throughout the wall thickness, with higher heat resistance near the combustion side and higher structural integrity near the cooling side, thereby improving both thermal protection and durability simultaneously
Solution Approach 2:
The combustor wall utilizes functionally graded composite materials with varying composition through the thickness. This composite structure combines materials with different thermal and mechanical properties in a gradient distribution, enabling the wall to resist both thermal stress and mechanical fatigue, thus improving reliability while maintaining thermal protection
2Reliability
If additive manufacturing is used to create monolithic cooled walls, then durability is improved, but manufacturing complexity increases
Solution Approach 1:
The patent combines multiple manufacturing steps and material deposition processes into a single additive manufacturing operation. The monolithic structure is built layer-by-layer in one continuous process, integrating cooling channels, material gradients, and structural features simultaneously, which improves durability while managing manufacturing complexity through process integration
Solution Approach 2:
The additive manufacturing process enables precise control and gradual change of material composition parameters during construction. By varying material feedstock composition, layer density, and processing parameters dynamically during manufacturing, the patent achieves functionally graded structures with improved durability while maintaining manufacturing feasibility through parameter optimization
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 provides increased durability and thermal protection, reducing the likelihood of cracking and extending the lifespan of combustor panels by effectively managing thermal and mechanical stresses through advanced material distribution and cooling mechanisms.
Implementation Method 1
using a laser or electron beam to melt or sinter the material to form a cross section
Implementation Method 2
using a laser or electron beam to melt or sinter the material to form a cross section
Implementation Method 3
cooling air flows through the axial channels
Data Source
AI summary
A cooled wall for lining a combustor of a gas turbine engine includes an annular outer wall defining a radial passage extending therethrough, an inner wall spaced radially from the outer wall to define an axial channel in fluid communication with the radial passage, and a connecting wall joining the inner wall to the outer wall. A method of making the cooled wall includes providing a three-dimensional computer model of the cooled wall, depositing a uniform thickness layer of material on a substrate, using a laser or electron beam to melt or sinter the material to form a cross section, repeating the depositing and cross section steps to form the cooled wall, and heat treating the cooled wall.