Gas Turbine Manifold Segmented Cladding Corrosion Protection
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Solution Overview
Problem
Gas turbine components, particularly combustor fuel manifolds, face challenges in applying corrosion-resistant cladding due to their enclosed and difficult-to-reach nature, leading to corrosion issues and increased repair costs.
Innovation Solution
A method of forming a corrosion-resistant cladding layer by joining two substrate sections with mating ridges, overlaying the interior surface of a plenum with a nickel-based alloy, such as INCONEL 625, using techniques like welding or brazing, and optionally employing an additive root pass to enhance the cladding's integrity and prevent contamination by non-corrosion-resistant materials.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional cladding methods are used on enclosed plenums, then corrosion protection is achieved, but the manufacturing complexity and difficulty increase significantly
Solution Approach 1:
The manifold is divided into multiple segments that can be assembled around the plenum, allowing the cladding to be applied to accessible exterior surfaces rather than attempting to reach enclosed interior surfaces. This segmentation transforms an inaccessibility problem into a manageable assembly problem.
Solution Approach 2:
Instead of applying cladding to the interior surface of the plenum (traditional approach), the invention applies cladding to the exterior surface and uses segmented construction to achieve protection. This inversion of the cladding application approach eliminates the accessibility problem while maintaining corrosion protection.
2Duration of action of stationary object
If corrosion-resistant materials are applied to interior surfaces, then service life is extended, but manufacturing time and cost increase
Solution Approach 1:
The corrosion-resistant cladding is applied to the exterior surfaces of manifold segments during the initial manufacturing process, before assembly into the final configuration. This preliminary application of protective material eliminates the need for time-consuming interior cladding operations after assembly.
Solution Approach 2:
The segmented manifold structure acts as an intermediary that allows exterior cladding to provide interior protection. The segments are assembled to enclose the plenum, with the externally-applied cladding on each segment contributing to overall interior surface protection without requiring direct interior application.
3Object-affected harmful factors
If complex cladding procedures are used on difficult-to-reach surfaces, then corrosion resistance is improved, but device complexity increases
Solution Approach 1:
The manifold system is segmented into multiple manageable sections that can be independently clad and then assembled. This segmentation simplifies the cladding process by working on smaller, accessible exterior surfaces rather than attempting to clad complex enclosed interiors as a single unit.
Solution Approach 2:
The invention changes the spatial parameter of cladding application from interior to exterior surfaces, and changes the structural parameter from monolithic to segmented construction. These parameter changes transform a complex inaccessibility problem into a simple exterior application process.
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 method efficiently and cost-effectively reduces corrosion on gas turbine manifolds, extends their service life, and decreases repair costs by providing a robust, corrosion-resistant layer that protects against corrosive fluids.
Implementation Method 1
overlaying the interior surface of a plenum with a nickel-based alloy, such as INCONEL 625, using techniques like welding or brazing
Implementation Method 2
overlaying the interior surface of a plenum with a nickel-based alloy, such as INCONEL 625, using techniques like welding or brazing
Data Source
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AI summary
Components (100) are disclosed which include a first component section (102) and a second component section (104) joined to form a hollow structure (106) defining a plenum (108) having an interior surface (110), wherein the component sections (102, 104) each include mating ridges (120, 122, 124, 126) joined together along the length (114) of the plenum (108), and a corrosion-resistant cladding layer (128) including a corrosion-resistant material (130) overlaying the interior surface (110) of the plenum (108). In one embodiment, the component (100) is a gas turbine combustor fuel manifold (604). A method of forming the components (100) includes applying corrosion-resistant segments (134, 136) including a corrosion-resistant material (130) to each of the surfaces (200, 300) of the component sections (102, 104), and joining the component sections (102, 104) to form the component (100), wherein joining the component sections (102, 104) includes fusing the corrosion-resistant segments (134, 136) into the corrosion-resistant cladding layer (128), and joining the mating ridges (120, 122, 124, 126) of the component sections (102, 104).