Laser-Clad Fluid Nozzle Joint for Integrated Elbow Assembly
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional fluid nozzle joints in gas turbine engines require an intermediate elbow piece, increasing part count, cost, and weight, and machining thick tubes is costly and wasteful.
Innovation Solution
A method involving laser cladding material onto a tube stock to form a fluid passage and joint surfaces, eliminating the need for an elbow piece by creating a metallurgical joint with a single crystal structure boundary, and brazing a fluid nozzle directly to the joint surface.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If an intermediate elbow piece is used to join the fluid tube to the fluid nozzle, then the joint can be properly formed with suitable thickness for brazing and welding, but the part count and weight increase
Solution Approach 1:
The patent merges the fluid tube and elbow into a single integrated component formed from one piece of tube stock. The laser deposition process creates an elbow section directly attached to the feed tube, eliminating the need for a separate intermediate elbow piece while maintaining structural integrity and joint quality
Solution Approach 2:
The patent uses laser deposition to create a composite structure where metal powder is deposited and fused onto the tube stock to form the elbow section. This creates a metallurgical bond between the feed tube and elbow, achieving reliable joint quality without requiring additional intermediate components
2Reliability
If an intermediate elbow piece is used to join the fluid tube to the fluid nozzle, then the joint can be properly formed, but the manufacturing cost increases
Solution Approach 1:
The patent merges the fluid tube and elbow into a single integrated component formed from one piece of tube stock. The laser deposition process creates an elbow section directly attached to the feed tube, eliminating the need for a separate intermediate elbow piece while maintaining structural integrity and joint quality
Solution Approach 2:
The patent extracts the unnecessary intermediate elbow piece from the assembly, keeping only the essential feed tube and nozzle components. This simplification reduces part count and manufacturing complexity while maintaining joint quality through direct laser deposition bonding
3Ease of operation
If the elbow piece is omitted and a very thick tube is used for the fluid tube, then the tube can be bent to the required radius, but excessive material must be machined away which is expensive and wasteful
Solution Approach 1:
The patent performs preliminary shaping by laser depositing material in the exact geometry needed for the elbow section before final machining. This builds the elbow shape directly onto the tube stock, avoiding the need to start with excessively thick tube walls and machine away large amounts of material
Solution Approach 2:
The patent changes the material distribution parameters by selectively depositing metal powder only where needed to form the elbow section. This creates the required geometry with minimal material addition rather than starting with thick-walled tube and removing material
4Ease of operation
If the elbow piece is omitted and a very thick tube is used for the fluid tube, then the tube can be bent to the required radius, but the machining cost increases
Solution Approach 1:
The patent performs preliminary shaping by laser depositing material in the exact geometry needed for the elbow section before final machining. This builds the elbow shape directly onto the tube stock, avoiding the need to start with excessively thick tube walls and machine away large amounts of material
Solution Approach 2:
The patent replaces traditional mechanical machining operations with laser deposition technology. Instead of machining away excessive material from thick-walled tube, the laser process selectively adds material to form the elbow geometry, significantly reducing machining time and cost
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 part count and weight while allowing for lower-cost materials, minimizing waste, and facilitating efficient assembly of fluid injection components.
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
Figure 1~4
Figure 5~7
Figure 8~9
AI summary
A method of making a fluid injection component for a gas turbine engine includes depositing material onto a piece of tube stock (102). The method includes machining an elbow (110) into the deposited material, wherein machining the elbow (110) includes forming a braze joint surface in the deposited material. Depositing can include laser cladding the material onto the piece of tube stock (102).