Heat-Shielded Fluid Conduit Assembly for Thermal Expansion
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Solution Overview
Problem
Conventional methods for additive manufacturing of fluid conduits in gas turbine engines face challenges in maintaining effective heat shielding due to thermal connections between the fluid passage supports and the heat shield, which compromise insulation.
Innovation Solution
The method involves aligning at least a portion of the fluid conduit and heat shield beyond the maximum build angle during additive manufacturing, using supports that can be welded, bolted, or brazed to the heat shield, and incorporating elongated apertures to accommodate thermal expansion, with a ring-shaped manifold and feed arms for improved insulation and thermal management.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If supports are used to hold the fluid conduit during additive manufacturing, then the conduit can be formed with proper structural support, but thermal connection between the supports and heat shield compromises the insulation
Solution Approach 1:
The patent extracts the support structure from the final product design, using temporary supports only during the additive manufacturing process. These supports are removed after manufacturing, eliminating the thermal connection pathway while preserving the conduit's structural integrity that was maintained during building.
Solution Approach 2:
The patent introduces thermal insulation material as an intermediary between the supports and the heat shield. This mediator reduces thermal conduction through the supports while allowing them to perform their structural function of holding the conduit in place during manufacturing.
2Loss of energy
If the heat shield is positioned close to the fluid conduit for effective shielding, then thermal insulation is improved, but thermal expansion and contraction cause misalignment and potential damage
Solution Approach 1:
The patent makes the support structure dynamic by incorporating flexibility that allows it to accommodate thermal expansion and contraction. The supports can flex and adjust their position as the conduit and heat shield expand and contract at different rates, maintaining proper alignment without causing structural damage.
Solution Approach 2:
The patent changes the physical parameters of the support structure by using elongated apertures instead of fixed rigid connections. This allows the supports to move and adjust their position, accommodating the differential thermal expansion between the conduit and heat shield while maintaining structural integrity.
3Manufacturing precision
If rigid supports are used to maintain precise positioning, then manufacturing accuracy is achieved, but the structure cannot accommodate differential thermal expansion
Solution Approach 1:
The patent transforms the rigid support structure into a dynamic one by using elongated apertures that allow movement. This enables the supports to maintain precise positioning during manufacturing while adapting to thermal expansion differences during operation, combining both requirements in a single design.
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 enhances the thermal insulation of fluid conduits by minimizing thermal connections, allowing for effective heat shielding and accommodating thermal expansion, thereby improving the performance of fluid conduits in gas turbine engines.
Implementation Method 1
Fluid passages such as used for fuel need to be insulated from heat
Implementation Method 2
heat shield extends about the fluid conduit in a manner that shields the fluid conduit from heat
Implementation Method 3
At least some of the apertures through the heat shield can be elongated to accommodate relative thermal expansion/contraction between the fluid conduit and the heat shield
Data Source
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AI summary
A method includes forming a fluid conduit (102) inside a heat shield (104) in an additive manufacturing process, removing powder from an interior passage (110) of the fluid conduit and from an insulation gap (112) defined between the fluid conduit and the heat shield, separating the heat shield and fluid conduit from the build platform, and shifting the fluid conduit to a shifted position relative to the heat shield. The method includes securing the fluid conduit to the heat shield in the shifted position.