Fuel Nozzle Joint Elbow Built by Laser Cladding
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Solution Overview
Problem
Existing fluid injectors for gas turbine engines require an intermediate elbow piece to connect the fluid tube to the nozzle, increasing part count, cost, and weight due to the need for precision machining and joining.
Innovation Solution
A method involving laser cladding to deposit material onto a tube stock, machining an elbow into the deposited material to form a joint surface, and brazing a fluid nozzle to the joint, thereby eliminating the need for an intermediate elbow piece.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If an intermediate elbow piece is used to connect the fluid tube to the nozzle, then the joint can be precisely machined and joined, but the part count, cost, and weight increase
Solution Approach 1:
The patent merges the fluid tube and elbow into a single integrated component by depositing material onto the tube to form the elbow directly, eliminating the need for separate elbow pieces and reducing part count while maintaining joint precision through controlled material deposition and machining
2Manufacturing precision
If an intermediate elbow piece is used to connect the fluid tube to the nozzle, then the joint can be precisely machined and joined, but the weight increases due to extra parts and joining materials
Solution Approach 1:
The patent merges the fluid tube and elbow into a single integrated component, eliminating the weight of separate elbow pieces and joining materials (brazing/welding) while maintaining joint precision through controlled material deposition and machining processes
3Device complexity
If a very thick tube is used to omit the elbow piece, then the part count is reduced, but the material waste and machining cost increase significantly
Solution Approach 1:
The patent applies preliminary material deposition onto the tube surface before machining, allowing the elbow shape to be formed with minimal material removal. This preliminary action of depositing material only where needed significantly reduces material waste compared to machining a thick tube down to the final shape
Solution Approach 2:
The patent changes the manufacturing approach from subtractive machining of thick material to additive deposition followed by minimal machining, altering the material parameter utilization from high waste to low waste while reducing part count
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 part count and weight, lowers production costs, and allows for the use of lower-cost materials, while minimizing waste material compared to traditional machining methods.
Implementation Method 1
Depositing can include laser cladding the material onto the piece of tube stock
Implementation Method 2
The method can include brazing a fluid nozzle to the joint surface of the deposited material
Data Source
AI summary
A method of making a fluid injection component for a gas turbine engine includes depositing material onto a piece of tube stock. The method includes machining an elbow into the deposited material, wherein machining the elbow includes forming a braze joint surface in the deposited material. Depositing can include laser cladding the material onto the piece of tube stock.