Segmented Annular Combustion Chamber Assembly
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Solution Overview
Problem
Conventional manufacturing methods for annular combustion chambers are expensive and time-consuming, requiring multiple techniques such as casting, forging, rolling, machining, and welding, leading to long lead times and high costs.
Innovation Solution
The combustion chamber is composed of multiple segments with distinct portions that are bolted together, allowing for simplified assembly and replacement, with segments formed through casting or advanced methods like direct laser deposition or selective laser sintering, eliminating the need for complex joining processes and machine tools.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional manufacturing methods (casting, forging, rolling, machining, welding) are used to manufacture annular combustion chambers, then manufacturing precision and structural integrity are improved, but manufacturing cost and lead time increase significantly
Solution Approach 1:
The annular combustion chamber is divided into multiple segments that can be manufactured separately and assembled together. Each segment can be produced using simpler casting methods rather than complex forging and machining operations, significantly reducing manufacturing lead time while maintaining structural integrity through proper joint design
2Reliability
If conventional manufacturing methods (casting, forging, rolling, machining, welding) are used to manufacture annular combustion chambers, then structural integrity and durability are improved, but manufacturing cost increases
Solution Approach 1:
The combustion chamber is segmented into multiple sections that can be manufactured using cost-effective casting methods rather than expensive forging and machining operations. The segments are joined using simplified connection methods that maintain structural integrity while reducing overall manufacturing cost
Solution Approach 2:
Multiple manufacturing operations (casting, forging, rolling, machining, welding) that were traditionally required are merged into a single simplified process using segmented casting with integrated joint features, eliminating the need for separate forging, rolling, and machining steps
3Strength
If conventional manufacturing methods are used, then structural strength is improved, but device complexity and number of manufacturing processes increase
Solution Approach 1:
The combustion chamber is divided into segments that can be manufactured using a single standardized process, reducing manufacturing process complexity. The segmentation allows each segment to be produced independently using simple casting techniques, eliminating the need for multiple specialized manufacturing processes
Solution Approach 2:
The segmented design with standardized joints creates a universal manufacturing approach that can be applied to different combustion chamber configurations. The same basic segment design and joining methodology can be used across various applications, reducing the complexity of manufacturing processes
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
This approach reduces manufacturing costs and lead times, enables easier repair, and allows for the construction of a double-wall combustion chamber using hand tools, without the need for forgings or sheet metal forming, while maintaining efficiency and durability.
Implementation Method 1
The plurality of cooling holes may be arranged to impinge the coolant upon a radially outer surface of the third portion of the adjacent segment
Implementation Method 2
The third portion of each segment may have a plurality of effusion cooling apertures to provide a film of coolant on a radially inner surface of the third portion of each segment
Implementation Method 3
The third portion of each segment may have a thermal barrier coating on a radially inner surface
Data Source
AI summary
A combustion chamber includes at least one annular wall. The annular wall includes a plurality of segments and each segment has a first portion, a second portion and a third portion. The first portion of each segment extends circumferentially, the third portion of each segment extends circumferentially and the second portion of each segment extends radially to connect the first portion and third portion of the segment. The segments are arranged such that the first portion of each segment overlaps the third portion of an adjacent segment and the first portion of each segment is bolted to the third portion of the adjacent segment. The segments are cast and define a double wall combustion chamber and enable easier construction of the combustion chamber and replacement of damaged segments.