Fluid Injector Tube Cladding to Cut Waste and Machining Time
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Solution Overview
Problem
Conventional methods for manufacturing fluid injectors for gas turbine engines result in significant material waste and long machining times due to the need for large pieces of material that are machined down to their final shape, lacking an efficient and waste-reducing alternative.
Innovation Solution
A method involving laser cladding and machining to construct fluid injector components, such as prefilmer, fluid distributor, and outer air swirler, using deposition processes to minimize material waste and reduce machining time.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional machining methods are used to manufacture fluid injector components, then manufacturing precision can be achieved, but material waste is considerable and machining time is long
Solution Approach 1:
The patent applies preliminary action by depositing material onto tube stock before final machining. The material deposition process (such as laser cladding or plasma spraying) creates a pre-formed layer that requires minimal subsequent machining, thereby reducing material waste while maintaining manufacturing precision. The deposited material is applied in the exact configuration needed, eliminating the need to start with large blocks of material.
2Manufacturing precision
If conventional machining methods are used to manufacture fluid injector components, then manufacturing precision can be achieved, but machining time is considerable
Solution Approach 1:
The patent applies preliminary action by depositing material onto tube stock before final machining. The material deposition process (such as laser cladding or plasma spraying) creates a pre-formed layer that requires minimal subsequent machining, thereby reducing material waste while maintaining manufacturing precision. The deposited material is applied in the exact configuration needed, eliminating the need to start with large blocks of material.
Solution Approach 2:
The patent replaces traditional mechanical machining processes with material deposition processes. Instead of removing material through conventional machining operations, the invention uses deposition techniques (laser cladding, plasma spraying, or CVD) to build up the required component geometry directly on the tube stock, significantly reducing machining time while maintaining precision.
3Strength
If large pieces of material are used to ensure suitable braze length, then joint strength can be achieved, but material waste increases
Solution Approach 1:
The patent applies local quality by depositing material specifically at the locations where braze joints are needed. The deposition process creates localized material buildup with the exact geometry required for strong joints, rather than using large pieces of material throughout the entire component. This ensures suitable braze length and joint strength while minimizing overall material waste.
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
Reduces material waste and machining time while allowing the use of inexpensive materials for the tube body and specialized materials for critical components, enhancing the efficiency and cost-effectiveness of fluid injector production.
Implementation Method 1
depositing material onto a piece of tube stock, then machining the deposited material into a fluid injector component
Implementation Method 2
depositing material onto a piece of tube stock
Data Source
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AI summary
A method of making a fluid injector for a gas turbine engine includes depositing material (104) onto a piece of tube stock (102). The method includes machining the deposited material into a fluid injector component (106). Depositing can include laser cladding the material onto the piece of tube stock. The method can include placing or flowing braze into a braze joint location (116) between the deposited material and another fluid injector component and forming the braze into a braze joint in the braze joint location.