Monolithic Fuel Injection Nozzle via Direct Metal Laser Sintering
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Solution Overview
Problem
Existing gas turbine engine fuel injection nozzles face limitations in increasing fuel injector length due to manufacturing constraints, leading to potential leaky joints and the need for costly EDM procedures, which hinder efficient mixing and emission reduction.
Innovation Solution
A monolithic fuel injection head with integrally formed pre-mix tubes and fuel injectors, manufactured using direct metal laser sintering (DMLS), allowing for longer fuel injector channels and reduced thickness, thereby enhancing mixing efficiency and reducing emissions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-generated harmful factors
If the fuel injector length is increased to enhance mixing efficiency, then emissions are reduced, but the pre-mix tube thickness must be increased which limits the number of tubes that can be included in the fuel nozzle
Solution Approach 1:
The patent combines multiple pre-mix tubes and fuel injectors into a single monolithic structure manufactured using direct metal laser sintering (DMLS). This integration eliminates the need for separate tube assemblies and braze joints, allowing for longer fuel injector channels while maintaining a compact overall structure that can accommodate numerous mixing tubes without increasing individual tube thickness.
Solution Approach 2:
The patent changes the manufacturing method from traditional braze joint assembly to direct metal laser sintering, which enables complex geometries with longer fuel injector channels. This parameter change in the manufacturing process allows the fuel injector length to exceed conventional limitations while reducing the number of joints and improving mixing efficiency.
2Ease of manufacture
If traditional braze joint assembly methods are used to manufacture fuel injection nozzles, then manufacturing is simpler, but leaky joints occur and costly EDM procedures are required
Solution Approach 1:
The patent merges multiple components (pre-mix tubes, fuel injectors, and sealing structures) into a single monolithic piece manufactured by direct metal laser sintering. This eliminates braze joints entirely, removing the source of leaks while the additive manufacturing process inherently creates sealed internal channels. The single-piece construction achieves both manufacturing simplicity and joint sealing reliability.
Solution Approach 2:
The patent replaces the mechanical braze joint assembly system with an additive manufacturing system that directly forms the complex internal geometry. This substitution eliminates the need for EDM procedures and braze joint assembly, achieving both ease of manufacture and reliable sealing through the DMLS process alone.
3Object-generated harmful factors
If the pre-mix tube thickness is increased to accommodate longer fuel injectors, then mixing efficiency improves, but the number of tubes that can be included in the fuel nozzle decreases
Solution Approach 1:
The patent integrates the fuel injector as an integral part of the pre-mix tube structure in a monolithic component. This merging allows the fuel injector channel to extend beyond the tube wall thickness limitation, achieving longer mixing paths without increasing the external tube dimensions. The unified structure enables longer injectors while maintaining a compact arrangement that fits more tubes in the nozzle.
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 DMLS process enables the production of fuel injection nozzles with increased pre-mix tube count and longer fuel injector channels, improving fuel and air mixing, leading to higher engine efficiency and lower emissions while eliminating the need for costly machining and braze joints.
Implementation Method 1
manufactured using direct metal laser sintering (DMLS)
Data Source
AI summary
A fuel injection head for use in a fuel injection nozzle comprises a monolithic body portion comprising an upstream face, an opposite downstream face, and a peripheral wall extending therebetween. A plurality of pre-mix tubes are integrally formed with and extend axially through the body portion. Each of the pre-mix tubes comprises an inlet adjacent the upstream face, an outlet adjacent the downstream face, and a channel extending between the inlet and the outlet. Each pre-mix tube also includes at least one fuel injector that at least partially extends outward from an exterior surface of the pre-mix tube, wherein the fuel injector is integrally formed with the pre-mix tube and is configured to facilitate fuel flow between the body portion and the channel.