Gas Turbine Nozzle Synchronization Ring Additive Manufacturing
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Solution Overview
Problem
Conventional gas turbine engine nozzle systems face challenges in optimizing thrust and fuel efficiency due to limitations in variable area ratio adjustments and actuator loads, particularly in achieving lightweight yet rigid interfaces for nozzle section support.
Innovation Solution
A convergent/divergent nozzle system with curved aft sections of convergent flap rails, tracks for flap support, pivotally coupled links, and a synchronization ring that can be additively manufactured, allowing for precise control of nozzle throat and exit areas through axial movement and reduced actuator loads.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If conventional nozzle systems use traditional interface structures, then structural support is provided, but weight reduction and rigidity are limited
Solution Approach 1:
The synchronization ring is manufactured using additive manufacturing (3D printing) technology, which enables the creation of complex lattice structures and optimized material distribution. This composite approach allows the interface structure to achieve high rigidity-to-weight ratio by strategically placing material only where structurally necessary, rather than using solid conventional materials throughout.
Solution Approach 2:
The nozzle system is divided into modular components including the synchronization ring, convergent flap rails, divergent flap rails, and linkage mechanisms. This segmentation allows each component to be independently optimized for weight and strength, with the additive-manufactured synchronization ring serving as a lightweight yet rigid central interface element that coordinates all other components.
2Productivity
If the nozzle area ratio range is increased for better performance, then thrust and fuel efficiency improve, but actuator loads increase
Solution Approach 1:
The nozzle system employs dynamic flap mechanisms that can articulate through a wide area ratio range (1.0 to 2.0 or greater). The synchronization ring with its integrated linkage system enables smooth, coordinated movement of multiple flaps simultaneously, distributing the mechanical loads across multiple actuators rather than requiring single high-load actuators, thus achieving large area ratio changes with reduced individual actuator loads.
Solution Approach 2:
The synchronization ring merges the coordination function for multiple flaps into a single integrated component. By combining the motion control of convergent and divergent flaps through a unified additive-manufactured ring structure, the system achieves synchronized movement that optimizes thrust vectoring while distributing actuator loads across the integrated mechanism rather than concentrating forces on individual actuators.
3Manufacturing precision
If traditional manufacturing methods are used for the synchronization ring, then manufacturing is simpler, but positional accuracy and deflection control are reduced
Solution Approach 1:
Additive manufacturing enables precise control over geometric parameters of the synchronization ring, including wall thickness, lattice structure dimensions, and feature locations. This manufacturing method achieves positional accuracy of flap mechanisms by directly printing complex 3D geometries with high precision, eliminating the need for traditional multi-step machining processes while maintaining or improving dimensional tolerances.
Solution Approach 2:
The additive-manufactured synchronization ring incorporates local quality variations through its lattice structure and variable wall thicknesses. Material is strategically placed only where structural support and precision are needed, such as at flap attachment points and linkage interfaces, while other areas use reduced material. This local optimization achieves high positional accuracy at critical interfaces without uniformly increasing device complexity throughout the entire structure.
Data Source
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AI summary
A nozzle system includes a static structure (52) including a multiple of convergent flap rails (114) and a synchronization ring (80) including an inner ring (90) radially spaced from an outer ring (94) via a multiple of struts (130). The multiple of convergent flap rails (114) extend at least partially between the inner ring (90) and the outer ring (94).