Additive Manufactured Fuel Nozzle Core for Gas Turbine Engine
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Solution Overview
Problem
The manufacturing of fuel nozzles and swirlers for gas turbine engines is complex and requires innovative methods to simplify the process while maintaining effectiveness.
Innovation Solution
The method involves additive manufacturing of a sacrificial core made from refractory metal alloys, ceramics, or hybrid materials to create the internal geometry of fuel components, such as fuel nozzles, using techniques like Direct Metal Laser Sintering, which allows for the creation of complex structures with reduced assembly details and multi-component construction.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If traditional manufacturing methods are used for fuel nozzles and swirlers, then the components can be produced with standard processes, but the manufacturing process is complex and requires multiple components and assembly steps
Solution Approach 1:
The patent combines multiple separate components (fuel nozzle body, swirlers, internal passages, and support structures) into a single integrated component manufactured via additive manufacturing. This merging eliminates the need for assembly of multiple parts and simplifies the manufacturing process while maintaining all required functional features.
Solution Approach 2:
The design separates the sacrificial core (which defines internal geometry) from the final functional component. The sacrificial core is additively manufactured with precise internal geometries that are later replicated in the final component, allowing complex internal features to be created without complex tooling or assembly procedures.
2Manufacturing precision
If traditional manufacturing methods are used, then standard processes can be applied, but complex internal geometries are difficult to achieve
Solution Approach 1:
The sacrificial core is pre-manufactured with the exact internal geometry required for the final component. This preliminary action allows complex internal passages and features to be defined with high precision before the final component is formed, eliminating the need for complex post-processing or assembly operations.
Solution Approach 2:
The sacrificial core acts as an intermediary tool that defines the internal geometry of the final component. By using this intermediate element, complex internal features can be created with high precision through a simple replication process, avoiding the need for complex direct manufacturing methods.
3Device complexity
If multiple components are used to achieve complex internal geometries, then the internal features can be created, but the assembly process becomes more complex
Solution Approach 1:
The patent merges the function of multiple separate components (nozzle body, swirlers, internal passages, and support structures) into a single additively manufactured component. This integration maintains all required internal geometries and functional features while completely eliminating assembly operations.
Solution Approach 2:
Instead of assembling multiple components to create internal geometries, the invention inverts the approach by using a sacrificial core with the desired internal geometry that is then replicated in the final component. This inversion eliminates assembly complexity while maintaining internal geometry capability.
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 simplifies the manufacturing process by enabling the production of complex internal geometries within fuel components, reducing assembly complexity and enhancing the efficiency of fuel nozzle production.
Implementation Method 1
additive manufacturing of a sacrificial core... using techniques like Direct Metal Laser Sintering
Data Source
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AI summary
A method of manufacturing a fuel component for a gas turbine engine combustor includes additive manufacturing a sacrificial core and manufacturing a fuel component body at least partially around the sacrificial core. The sacrificial core is at least partially removed to at least partially define an internal geometry of the fuel component. An additively manufactured sacrificial core for a fuel component of a gas turbine engine combustor includes a first structure and a second structure. The first structure at least partially defines a first passage of the fuel component. The second structure at least partially defines a second passage of the fuel component. The second structure at least partially surrounds the first structure.