Additive Manufactured Fluid Nozzle Heat Shielding
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Solution Overview
Problem
Conventional methods for manufacturing fluid nozzles within gas turbine engines using additive manufacturing face challenges in maintaining effective heat shielding due to thermal connections between fluid passages and heat shields, which compromise insulation.
Innovation Solution
A method involving the formation of fluid conduits and nozzles within a heat shield using additive manufacturing, where the nozzle is defined at the downstream end, and the heat shield is formed around it, allowing for the removal of powder from interior passages and insulation gaps, followed by shifting and securing the conduit and nozzle to reduce thermal gaps and maintain insulation, using supports that extend through apertures in the heat shield and can accommodate thermal expansion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If fluid passages are supported during additive manufacturing using supports, then the internal fluid passage can be formed, but the supports create thermal connections between the conduit and heat shield that undermine heat shielding
Solution Approach 1:
The patent removes the supports after the additive manufacturing process is complete, extracting the temporary structural element that caused thermal bridging. This allows the heat shield to function properly without thermal connections to the fluid conduit, while still enabling the conduit to be formed during manufacturing.
Solution Approach 2:
The patent introduces an insulating material as an intermediary between the fluid conduit and heat shield. This mediator prevents thermal energy transfer while allowing the structural relationship to be maintained, solving the thermal bridging problem created by supports.
2Object-affected harmful factors
If the heat shield is formed tightly about the fluid nozzle, then heat shielding effectiveness is improved, but thermal expansion and contraction may cause stress or misalignment
Solution Approach 1:
The heat shield is divided into multiple segments or sections that can move independently relative to each other. This segmentation allows the structure to accommodate thermal expansion and contraction without creating excessive stress, while maintaining overall heat shielding effectiveness.
Solution Approach 2:
The patent applies different properties to different parts of the heat shield structure. Certain regions have enhanced insulation properties or flexible connections to handle thermal stress locally, while other regions maintain rigid structural support. This localized differentiation allows the system to handle thermal cycling while maintaining shielding effectiveness.
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 enables the additive manufacture of fluid conduits and nozzles with improved heat shielding, reducing thermal connections and maintaining insulation effectiveness, thus enhancing the performance of fluid passages in gas turbine engines.
Implementation Method 1
Fluid nozzles such as used for fuel need to be insulated from heat
Implementation Method 2
forming a fluid conduit inside a heat shield in an additive manufacturing process
Data Source
AI summary
A method includes forming a fluid conduit inside a heat shield in an additive manufacturing process, wherein a fluid nozzle is defined at a downstream end of the fluid conduit, and wherein the heat shield is formed about the fluid nozzle. The method includes removing powder from an interior passage of the fluid conduit and fluid nozzle and from an insulation gap defined between the heat shield and the fluid conduit and fluid nozzle. The method includes separating the heat shield, fluid conduit, and fluid nozzle from the build platform. The method includes shifting the fluid conduit and fluid nozzle to a shifted position relative to the heat shield, and securing the fluid conduit and fluid nozzle to the heat shield in the shifted position.