Monolithic Turbine Engine Support Structure With Tapered Airflow Ports
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Solution Overview
Problem
Existing stationary engine structures in gas turbine engines require improvements for enhanced structural integration and airflow management.
Innovation Solution
A monolithic body comprising a combustor wall, engine case, and support structure with integrated ports and struts that facilitate fluid coupling between a plenum and combustion chamber, featuring tapered cross-sectional geometries for optimized airflow.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If traditional separate component structures are used for engine case, combustor wall, and support structure, then manufacturing and assembly are simpler for each individual component, but the overall structural integrity and airflow management efficiency are reduced
Solution Approach 1:
The patent combines the engine case, combustor wall, and support structure into a single monolithic body formed through additive manufacturing. This integration eliminates the need for separate components and their associated fasteners and joints, thereby improving structural integrity while reducing overall assembly complexity. The single-piece construction ensures continuous material flow and eliminates weak points at component interfaces.
Solution Approach 2:
The monolithic body performs multiple functions simultaneously: it serves as the engine case housing, the combustor wall structure, and the support structure with integrated airflow ports. This multi-functionality reduces the number of separate components needed while maintaining or enhancing structural performance and airflow management capabilities.
2Ease of operation
If multiple separate components are used for support structure, then manufacturing and maintenance are easier for individual parts, but airflow pathways and structural integration are compromised
Solution Approach 1:
The airflow ports are integrated directly into the monolithic body during additive manufacturing, creating seamless and precisely controlled airflow pathways. This integration eliminates the need for separate airflow management components and their associated seals and joints, improving airflow efficiency while reducing the number of manufacturing steps required for final assembly.
Solution Approach 2:
The additive manufacturing process enables complex port geometries and tapered cross-sections that would be difficult or impossible to achieve with traditional machining of separate components. This allows for optimized airflow pathways with varying cross-sectional areas along their length, improving airflow management while reducing assembly complexity.
3Manufacturing precision
If traditional machining methods are used for support structure, then manufacturing precision is achieved for standard geometries, but complex tapered port geometries and integrated structures cannot be efficiently produced
Solution Approach 1:
The additive manufacturing process fundamentally changes the manufacturing approach from subtractive machining to layer-by-layer construction, enabling the creation of complex tapered port geometries and integrated structures with high precision. This process can directly produce varying cross-sectional areas and three-dimensional features that would require multiple machining operations and tool changes with traditional methods.
Solution Approach 2:
Additive manufacturing adds a temporal dimension to the manufacturing process, building structures layer by layer in the third dimension. This enables the creation of complex three-dimensional port geometries with tapered cross-sections and integrated features that cannot be efficiently produced by traditional two-dimensional machining operations.
Data Source
AI summary
An assembly is provided for a turbine engine. This engine assembly includes a combustor, an engine case, a support structure and a monolithic body. The combustor includes a combustor wall and a combustion chamber within the combustor. The combustor wall forms a peripheral boundary of the combustion chamber. The engine case forms a peripheral boundary of a plenum along the combustor. The support structure extends radially from the combustor wall to the engine case. The monolithic body includes the combustor wall, the engine case, the support structure and a plurality of ports arranged circumferentially about an axis. Each of the ports is fluidly coupled with the plenum and projects axially through the support structure. The ports include a first port. The first port includes a cross-sectional geometry that laterally tapers as the first port extends radially outward within the monolithic body.