Monolithic Combustor Additive Manufacturing Miniature Gas Turbine
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Solution Overview
Problem
Miniature gas turbine engines for small aircraft applications face challenges in achieving economically feasible extended range with high starting and operational reliability, as existing designs are costly and complex to manufacture.
Innovation Solution
A monolithic combustor design for miniature gas turbine engines, featuring a diamond-shaped injector port, gusset, chamfered aft inner corner, and complementary geometry with the turbine wheel, is fabricated using additive manufacturing, reducing part count, weight, and manufacturing time.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If traditional multi-part combustor designs are used, then structural strength and sealing are improved, but manufacturing cost and complexity increase
Solution Approach 1:
The patent combines multiple combustor components (combustor liner, turbine nozzle, and turbine wheel) into a single monolithic structure fabricated via additive manufacturing. This merging eliminates the need for separate parts and complex assembly while maintaining structural integrity through the continuous material structure inherent in additive manufacturing processes.
2Ease of operation
If traditional multi-part combustor designs are used, then assembly and disassembly are improved, but weight and manufacturing time increase
Solution Approach 1:
The patent integrates the combustor liner, turbine nozzle, and turbine wheel into one monolithic component, eliminating assembly steps and reducing the total number of parts. This merging reduces weight by removing unnecessary joints, fasteners, and sealing elements while simplifying installation and maintenance operations.
3Productivity
If additive manufacturing is used for monolithic combustor, then manufacturing cost and time are reduced, but manufacturing precision challenges increase
Solution Approach 1:
The patent utilizes additive manufacturing parameters (layer thickness, infill density, support structure configuration) to optimize both manufacturing efficiency and dimensional precision. By carefully controlling these parameters, the process achieves the required tolerances for combustor components while maintaining rapid production capabilities.
4Device complexity
If monolithic design is used, then part count and cost are reduced, but structural complexity in design increases
Solution Approach 1:
The patent leverages the third dimension in additive manufacturing to create complex internal geometries and features that would be difficult or impossible to achieve with traditional manufacturing. This allows the monolithic design to incorporate necessary structural complexity for strength and function while eliminating the need for multiple separate parts.
Data Source
Figure 1
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Figure 3A
AI summary
A monolithic combustor apparatus comprises an outer casing (60) comprising a forward flange (61), a fuel manifold (52) disposed on the outer casing and defining an annular chamber extending perimetrically around the outer casing, a combustor liner (46) disposed within the outer casing, the combustor liner defining an annular combustion chamber (47), a first annular plenum disposed between the outer casing and the combustor liner, an inner liner (48) disposed radially from the combustor liner, a first inner flange (62) extending forward from the combustor liner, and a second inner flange (63) extending radially inward from the first inner flange (62).