Gas Turbine Engine Assembly with Monolithic Stationary Sections
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Solution Overview
Problem
Existing stationary engine structures for gas turbine engines, composed of tubular axial case segments connected by flange connections, require improvements in manufacturing and assembly methods to enhance structural integrity and reduce thermal distortion impacts on fuel delivery systems.
Innovation Solution
A stationary engine structure is designed as a monolithic, tubular assembly with discrete sections that are additively manufactured and bonded using flange and brazed connections, strategically positioned to minimize thermal distortion and facilitate inspection and finishing of fuel delivery components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If tubular axial case segments are connected by flange connections, then the stationary engine structure can be assembled from discrete components, but thermal distortion occurs affecting fuel delivery system alignment
Solution Approach 1:
The patent merges multiple discrete case segments into a monolithic, integrally-formed stationary engine structure. This eliminates the flange connections between segments that caused thermal distortion and fuel injector misalignment, while maintaining the ability to manufacture the structure through additive manufacturing processes.
2Ease of manufacture
If discrete case segments are used, then manufacturing and assembly are simplified, but structural integrity and thermal stability are reduced
Solution Approach 1:
The patent combines multiple case segments into a single monolithic structure that provides enhanced thermal stability and structural integrity. The integral formation eliminates gaps and connection points that would otherwise allow thermal distortion, while the additive manufacturing process enables complex geometries that would be difficult to achieve with traditional discrete assembly.
3Ease of operation
If flange connections are used between case segments, then assembly is facilitated, but thermal distortion affects fuel delivery components
Solution Approach 1:
The patent eliminates flange connections by forming a monolithic structure, thereby removing the source of thermal distortion that affected fuel delivery component alignment. The single-piece construction ensures consistent thermal characteristics throughout the engine structure, improving the reliability of fuel injection timing and positioning.
4Manufacturing precision
If monolithic structure is formed, then thermal distortion is minimized, but manufacturing complexity increases
Solution Approach 1:
The patent utilizes additive manufacturing technology to create the monolithic structure, representing a fundamental change in the manufacturing parameter from traditional subtractive or assembly-based methods. This enables the production of complex monolithic geometries that would be impossible or extremely difficult to manufacture using conventional processes, while achieving superior thermal distortion characteristics.
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 solution provides a robust, thermally stable engine structure with aligned fuel injectors, reducing misalignment and enhancing the efficiency and reliability of the gas turbine engine.
Implementation Method 1
discrete sections that are additively manufactured and bonded using flange and brazed connections
Data Source
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AI summary
An assembly is provided for a gas turbine engine (20). This gas turbine engine (20) assembly includes a stationary engine structure (34). The stationary engine structure (34) includes a diffuser (60), a combustor (50), an engine case (112) and a plenum (58). The combustor (50) is disposed within the plenum (58). The engine case (112) forms a peripheral boundary of the plenum (58). A gas path (40) extends sequentially through the diffuser (60), the plenum (58) and the combustor (50). A first section (121) of the stationary engine structure (34) is formed as a first monolithic body. The first section (121) includes the diffuser (60) and the combustor (50). A second section (122) of the stationary structure is formed as a second monolithic body. The second section (122) is configured as or otherwise includes the engine case (112).