Integral Combustor Liner and Turbine Nozzle Design

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Solution Overview

Problem

Attritable or expendable propulsion systems for small, unmanned aircraft require reliable and maintainable designs with minimal components, but existing systems are complex and difficult to manufacture efficiently, especially for single-use applications.

Innovation Solution

A core engine article is designed with an integral combustor liner and turbine nozzle, featuring diamond-shaped injector ports and self-supporting airfoils, manufactured using additive manufacturing techniques to reduce complexity and enhance performance, with features like webbing, scallops, and annuli to improve combustion efficiency and structural integrity.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If traditional separate-component design is used for combustor liner and turbine nozzle, then assembly flexibility is improved, but device complexity and manufacturing time increase

Engineering Contradiction:

Improvemanufacturing timeVSAvoidnumber of components

Core Design Contradiction:

Ease of manufactureVSDevice complexity

Solution Approach 1:

The patent merges the combustor liner and turbine nozzle into a single integral component manufactured via additive manufacturing. This eliminates the need for separate assembly of these components, reducing the total number of parts while maintaining functional performance. The additive manufacturing process enables complex geometries to be produced as one piece, directly addressing the contradiction between manufacturing efficiency and device complexity.

Inventive Principle:

Principle #5Merging (Combining)

2Ease of manufacture

If additive manufacturing is used for core engine article, then manufacturing complexity is reduced, but manufacturing precision requirements increase

Engineering Contradiction:

Improvemanufacturing complexityVSAvoiddimensional accuracy

Core Design Contradiction:

Ease of manufactureVSManufacturing precision

Solution Approach 1:

The patent employs parameter optimization in the additive manufacturing process, including build orientation, support structure design, and post-processing parameters. The injector ports are designed with specific dimensional parameters (e.g., 0.060-0.100 inches) that account for additive manufacturing tolerances. The design incorporates features like tapered corners and webbing that are optimized for the additive manufacturing process while maintaining functional precision.

Inventive Principle:

Principle #35Parameter changes

3Productivity

If injector ports have larger maximum dimension, then fuel injection efficiency is improved, but manufacturing precision difficulty increases

Engineering Contradiction:

Improvecombustion efficiencyVSAvoidport dimensional control

Core Design Contradiction:

ProductivityVSManufacturing precision

Solution Approach 1:

The patent applies local quality optimization by varying injector port dimensions and geometries based on specific functional requirements. Different ports have different maximum dimensions (0.060-0.100 inches) optimized for their specific injection needs. The ports feature tapered corners and webbing structures that are locally optimized for both combustion performance and additive manufacturing feasibility, balancing injection efficiency with manufacturing precision.

Inventive Principle:

Principle #3Local quality

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

The solution results in a reliable, efficient, and cost-effective propulsion system with reduced manufacturing complexity and time, enabling quick design iterations and improved combustion efficiency by minimizing air loss and maximizing structural integrity.

Implementation Method 1

depositing material using an additive manufacturing technique to form a turbine nozzle in a build direction and depositing material using the additive manufacturing technique to form a combustor liner in the build direction

Methodology Applied

Scientific EffectAdditive manufacturing: 3D Printing

Implementation Method 2

an aft end of the combustor liner includes one or more scallops, the scallops are configured to accelerate air flowing through the core engine article

Methodology Applied

Scientific EffectAirflow acceleration:

Implementation Method 3

a combustor liner defining a combustion chamber therein

Methodology Applied

Scientific EffectCombustion: Combustion

Data Source

PatentUS12053821B2Engine article with integral liner and nozzle

Publication Date: 2024.08.06 RTX CORP

AI summary

A core engine article includes a combustor liner defining a combustion chamber therein and a turbine nozzle. The combustor liner includes a plurality of injector ports, and the plurality of injector ports have a shape that tapers to a corner on a forward side of the injector ports. The turbine nozzle includes a plurality of airfoils. The combustor liner and turbine nozzle are integral with one another. A method of making a core engine article is also disclosed.