Integral Cast Manifold Conduits for Ceramic Core Removal

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Solution Overview

Problem

Current fuel manifolds for combustion turbine engines face manufacturing complexity and cost issues due to separate closeout fittings, restraint elements, and extraneous core holes formed during the casting process, which require additional machining and plugging operations.

Innovation Solution

The proposed solution involves an integral cast fuel manifold with fuel feed bosses and a pilot nozzle restraint formed as part of the base support structure, eliminating the need for fillet welded joints and extraneous core holes by using conduits for core removal, thereby simplifying the design and reducing manufacturing costs.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If separate closeout fittings and restraint elements are used in the base support structure, then the manifold can be assembled with modular components, but the manufacturing complexity and cost increase due to additional machining and welding operations

Engineering Contradiction:

Improvemodular assemblyVSAvoidmanufacturing complexity

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The patent integrates the closeout fittings, restraint elements, and fuel feed bosses directly into the base support structure as a single integral component. This merging eliminates the need for separate modular parts, thereby reducing manufacturing complexity and eliminating welding operations while maintaining the structural functionality of the manifold assembly

Inventive Principle:

Principle #5Merging (Combining)

2Ease of manufacture

If extraneous core holes are formed during the casting process for core removal, then the ceramic core can be extracted from the cast manifold, but additional plugging operations are required to seal the holes

Engineering Contradiction:

Improvecore removalVSAvoidassembly operations

Core Design Contradiction:

Ease of manufactureVSDevice complexity

Solution Approach 1:

The patent designs the base support structure with integrated conduits that provide dedicated pathways for extracting the ceramic core after casting. These conduits allow the core to be removed through existing structural openings without creating extraneous holes in the manifold body, thereby eliminating the need for subsequent plugging operations to seal unwanted holes

Inventive Principle:

Principle #2Taking out (Extraction)

3Ease of operation

If fillet welded joints are used to connect closeout fittings to the base support structure, then the fuel feeding tubes can be connected to the manifold, but the structural integrity and low cycle fatigue life are reduced

Engineering Contradiction:

Improveconnection capabilityVSAvoidstructural integrity

Core Design Contradiction:

Ease of operationVSReliability

Solution Approach 1:

The patent integrates the closeout fittings and restraint elements directly into the base support structure as a single integral component. This merging eliminates the need for separate modular parts, thereby reducing manufacturing complexity and eliminating welding operations while maintaining the structural functionality of the manifold assembly

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The patent replaces the mechanical welding connection system with an integral casting system where the closeout fittings and restraint elements are formed as part of the base support structure itself. This substitution eliminates the weak fillet welded joints and improves structural integrity and low cycle fatigue life

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Data Source

PatentUS10518321B2Casting method and manifold cast with conduits effective for removing a core from the cast without forming extraneous holes in the body of the manifold

Publication Date: 2019.12.31 SIEMENS ENERGY GLOBAL GMBH & CO KG

AI summary

A casting method and cast manifold are provided. The method allows configuring conduits, such as conduits in a fuel feed boss and/or a base rocket, which are part of the manifold for removing a ceramic core from the cast without forming extraneous holes in the body of the manifold. Absence of such extraneous holes in turn allows eliminating sealing plugs and welds, which otherwise would be needed for sealing the extraneous holes.