Erodible Support Structure for Additive Manufactured Combustor Walls
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Solution Overview
Problem
Additively manufactured components in gas turbine engines often require support structures during manufacturing, which can obstruct fluid flow and potentially break off during operation, causing issues with fluid flow and turbine component safety.
Innovation Solution
A method for forming a combustor with an additively manufactured support structure that is designed to be eroded by combustion flow, allowing it to be removed from the engine, and potentially combining with additional methods for complete removal, such as mechanical abrasion or chemical removal.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If monolithic support structures are used during additive manufacturing, then overhanging surfaces can be supported, but the support structures are difficult to mechanically remove and may obstruct fluid flow or break off during operation
Solution Approach 1:
The support structure's material properties are changed by applying a coating that modifies its response to combustion flow. The coating causes the support structure to erode and disintegrate under thermal and fluid dynamic conditions, transforming it from a permanent obstacle into a temporary manufacturing aid that self-removes during engine operation.
Solution Approach 2:
The support structure is designed as a temporary, disposable component that serves its purpose during manufacturing and then intentionally degrades during operation. The coating enables the support structure to be consumed by combustion flow, eliminating the need for permanent installation or complex removal mechanisms.
2Ease of manufacture
If support structures remain in the gas turbine engine, then mechanical removal complexity is reduced, but fluid flow is obstructed and turbine component safety is compromised
Solution Approach 1:
The harmful combustion flow and high-temperature environment that could damage engine components are instead utilized to remove the support structure. The combustion flow actively erodes and carries away the coated support structure, converting a potentially harmful factor into a useful removal mechanism.
Solution Approach 2:
The support structure self-removes through the combustion process without requiring external intervention. The coating enables the support structure to automatically degrade and be carried away by the combustion flow, eliminating the need for separate removal operations or complex disassembly procedures.
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 support structure is effectively removed from the combustor, preventing obstruction and reducing the risk of debris impacting turbine components, while ensuring smooth fluid flow and engine operation.
Implementation Method 1
the support structure is eroded by a combustion flow directed through the combustor
Data Source
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AI summary
A method for forming a combustor of a gas turbine engine includes additively manufacturing a combustor wall (68) of the combustor. The combustor wall (68) includes a component (72), projecting from a surface (70) of the combustor wall (68), and a support structure (76) in communication with the component (72) and the surface (70) of the combustor wall (68). The support structure (76) is a lattice structure (76).