Fluid Injector Material Deposition on Tube Stock to Cut Machining Waste
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Solution Overview
Problem
Conventional manufacturing methods for fuel injectors in gas turbine engines result in significant material waste and long machining times due to the need for large pieces of material that are often machined down to specific shapes, such as conical surfaces and braze joint surfaces.
Innovation Solution
A method involving the deposition of material onto tube stock using techniques like laser cladding, electron beam cladding, cold spraying, or plasma spraying, followed by machining to form fluid injector components, including prefilmers, feed arms, fluid distributors, and outer air swirlers, with braze joints formed to join these components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of substance
If conventional machining methods are used to form fuel injector components from large pieces of material stock, then structural integrity and component strength are maintained, but significant material waste is generated and machining time is considerable
Solution Approach 1:
The patent changes the manufacturing approach from subtractive machining to additive deposition, fundamentally altering the process parameter from removing material to adding material. This resolves the contradiction by enabling near-net-shape manufacturing that minimizes material waste while maintaining structural integrity through controlled deposition and post-deposition heat treatment processes
Solution Approach 2:
The patent applies preliminary action by depositing material to near-final dimensions before any machining operations. The additive deposition process creates components that are already close to their final shape, requiring minimal subsequent machining. This preliminary formation of the component geometry dramatically reduces material waste while maintaining manufacturing feasibility
2Manufacturing precision
If conventional machining methods are used to form conical surfaces and braze joint surfaces on prefilmers and fuel distributors, then precise surface geometry is achieved, but machining time is considerable
Solution Approach 1:
The patent changes the manufacturing parameter from mechanical machining to thermal deposition, allowing conical surfaces and braze joint surfaces to be formed through controlled material deposition rather than removal. This enables precise surface geometry to be achieved during the deposition process itself, with minimal post-machining required, thereby dramatically increasing productivity
Solution Approach 2:
The patent performs preliminary action by forming the required surface geometries including conical surfaces and braze joint surfaces during the additive deposition process itself. These surfaces are created in near-final form before any machining operations, eliminating the need for time-consuming subsequent machining while maintaining the required geometric precision
3Strength
If large pieces of material stock are used to accommodate braze joint surfaces and component features, then adequate material is available for joining and feature formation, but the amount of material that must be machined away increases
Solution Approach 1:
The patent applies local quality by depositing material with specific properties at specific locations where braze joints and features are required. Rather than using large pieces of uniform material, the additive process places material locally where needed, creating the necessary braze joint surfaces and component features only in those specific areas. This minimizes overall material usage while ensuring adequate material availability for joining operations
Solution Approach 2:
The patent performs preliminary action by forming braze joint surfaces and component features during the additive deposition process itself, before any machining or joining operations. This preliminary formation of joints and features ensures adequate material is available at the correct locations while minimizing the total amount of material that would otherwise need to be machined away
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 reduces material waste and machining time, allowing for the use of inexpensive tube materials with specialized high-temperature or hard materials only where needed, while maintaining structural integrity and efficiency in fluid injector construction.
Implementation Method 1
Depositing can include laser cladding
Implementation Method 2
Depositing can include electron beam cladding
Implementation Method 3
Depositing can include cold spaying
Implementation Method 4
Depositing can include plasma spraying
Data Source
AI summary
A method of making a fluid injector for a gas turbine engine includes depositing material onto a piece of tube stock. The method includes machining the deposited material into a fluid injector component. Depositing can include laser cladding the material onto the piece of tube stock. The method can include placing or flowing braze into a braze joint location between the deposited material and another fluid injector component and forming the braze into a braze joint in the braze joint location.