Additive Flame Tube Double-Wall Cooling for End Wall Durability
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Solution Overview
Problem
The existing manufacturing methods for flame tubes in turbomachines are lengthy, costly, and do not allow for easy modification of the geometry, leading to high thermal stresses in the end wall that can result in premature damage.
Innovation Solution
A method for manufacturing a flame tube using additive manufacturing, which involves creating a double wall with a flow channel for cooling air, allowing for the production of a complex structure in a single piece without the need for extensive machining or assembly, and reducing thermal stresses through effective cooling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If traditional manufacturing methods (pressing metal sheets and machining) are used, then the flame tube can be produced with conventional processes, but the manufacturing process is lengthy, costly, and requires extensive machining and assembly steps
Solution Approach 1:
The patent merges multiple manufacturing operations (forming, cooling channel creation, reinforcement addition) into a single additive manufacturing process. The flame tube is produced as an integral piece with double wall structure and cooling channels formed simultaneously, eliminating sequential machining and assembly steps required by traditional methods
Solution Approach 2:
The patent replaces traditional mechanical manufacturing methods (pressing, machining, drilling, assembly) with additive manufacturing technology. This substitution enables complex geometries to be built directly layer-by-layer without requiring extensive post-processing or multiple assembly operations
2Adaptability or versatility
If traditional manufacturing methods are used, then conventional production processes can be maintained, but geometry modification requires replacement of stamping dies which is particularly expensive
Solution Approach 1:
The patent enables geometry modification by changing digital design parameters in the additive manufacturing process. Unlike traditional stamping that requires physical die replacement, additive manufacturing allows geometric parameters to be modified through software updates, enabling cost-effective design iterations and customization
3Reliability
If single wall structure is used, then manufacturing is simpler, but the end wall is subject to high thermal stresses that must be reduced to prevent premature damage
Solution Approach 1:
The patent segments the end wall into a double wall structure with two separate walls spaced apart to form a cooling channel. This segmentation allows cooling air to flow through the channel, removing thermal stresses from the hot gas side and preventing premature damage to the flame tube end wall
Solution Approach 2:
The cooling channel acts as an intermediary between the hot gas environment and the end wall structure. By introducing cooling air through this intermediate channel, the patent mediates thermal stress transmission and protects the end wall from direct exposure to high temperatures
4Productivity
If additive manufacturing is used, then a complex structure can be produced in a single piece without extensive machining or assembly, but advanced manufacturing technology is required
Solution Approach 1:
The patent combines multiple manufacturing functions (forming, cooling channel creation, reinforcement integration) into a single additive manufacturing operation. This merging enables production of the complete flame tube assembly as one integral piece, significantly improving productivity by eliminating sequential operations
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 method enables the production of a finished or almost finished flame tube in a single piece, reducing production time and costs, while also effectively cooling the end wall to prevent damage and enhance mechanical strength.
Implementation Method 1
a flow channel for a flow of cooling air opening into the internal volume, the flow channel comprising at least one air inlet opening
Implementation Method 2
The connecting areas or bridges ensure the mechanical strength of the double wall
Data Source
AI summary
A method for manufacturing a flame tube for a turbomachine, the flame tube extending about an axis and comprising an annular radially internal wall and an annular radially external wall, connected to each other by an end wall or head wall, the internal wall, the external wall and the end wall defining an internal volume, at least one part of the said end wall forming a double wall comprising a first part and a second part connected to each other and spaced apart from each other so as to delimit a flow channel for a flow of cooling air opening into the said internal volume, the said flow channel comprising at least one air-inlet opening, the first and second parts of the double wall being connected by connecting zones or bridges extending into the flow channel for the cooling-air flow, the flame tube being manufactured by additive manufacturing.