Fuel Nozzle Tip Repair With Annular Coupon Replacement
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Solution Overview
Problem
Turbomachine fuel nozzle components experience wear due to vibrational and thermal stresses, leading to costly and time-consuming replacement of entire nozzles, rather than just worn sub-components.
Innovation Solution
A method involving the removal of material from the nozzle tip to form an annular groove, followed by the insertion and fixed coupling of a replacement coupon with increased wear resistance, restoring the interference fit between the nozzle tip and inner tube without replacing the entire nozzle.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the entire fuel nozzle is replaced when wear occurs, then reliability is restored, but cost and service time increase significantly
Solution Approach 1:
The fuel nozzle is divided into separable components: the nozzle body and the nozzle tip. The nozzle tip can be independently removed and replaced when worn, while the nozzle body remains in service. This segmentation allows repair of only the worn sub-component rather than replacing the entire nozzle, reducing service time and cost while restoring reliability.
Solution Approach 2:
The worn nozzle tip is discarded and replaced with a new or refurbished tip, while the remaining nozzle body is recovered and reused. This approach maximizes the utilization of the fuel nozzle components by replacing only the worn portion rather than the entire assembly, reducing waste and service time.
2Reliability
If the entire fuel nozzle is replaced when wear occurs, then reliability is restored, but service cost increases
Solution Approach 1:
The fuel nozzle is segmented into replaceable sub-components, allowing the nozzle tip to be independently replaced. This reduces material cost by reusing the worn nozzle body and only replacing the necessary tip portion, rather than discarding the entire nozzle assembly.
Solution Approach 2:
The worn nozzle tip is discarded and replaced, while the nozzle body is recovered and reused. This minimizes material waste and service cost by maximizing the utilization of the fuel nozzle components that are still functional.
3Manufacturing precision
If material is removed to form an annular groove and a replacement coupon is inserted, then the interference fit is restored, but manufacturing complexity increases
Solution Approach 1:
The repair process is segmented into distinct steps: removing material to form an annular groove, inserting the replacement coupon, and fixedly coupling it. This segmentation allows each step to be optimized independently, ensuring precise interference fit while managing overall process complexity through systematic organization.
Solution Approach 2:
The repair process changes the physical parameters of the nozzle tip by removing material to create an annular groove and then adding a replacement coupon. This parameter change restores the precise interference fit dimensions while the systematic approach to these changes manages the complexity of the repair process.
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 extends the life of the fuel nozzle by restoring the interference fit, reducing leaks and improving efficiency, and decreases the cost and time required for servicing by allowing for the repair of individual sub-components rather than entire nozzles.
Implementation Method 1
electron beam welding the first surface and the second surface to each other at the joining location
Data Source
Figure 1~2
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Figure 4
AI summary
Methods of servicing a fuel nozzle (100) are provided. a method of servicing a fuel nozzle (100) includes a step of machining away material (201) from a nozzle tip (115) of the fuel nozzle (100) to form an annular groove (208) within the nozzle tip (115). The method further includes a step of inserting a replacement coupon (214) into the annular groove (208). The replacement coupon (214) having a radially outermost that corresponds to the annular groove (208) and a post-removal contact surface (216). The method further includes a step of fixedly coupling the radially outermost of the replacement coupon (214) to the annular groove (208).