Single-Piece Combustor Casing for Gas Turbine Engines
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Solution Overview
Problem
Current gas turbine engine manufacturing processes are costly and time-consuming, particularly for applications requiring reduced size and lower production costs, such as drones and energy production, where traditional multi-piece constructions are inefficient and aerodynamically challenging.
Innovation Solution
A single-piece combustor casing component for gas turbine engines, featuring a combustor outer casing with blind holes, axial ribs, a pre-diffuser with apertures, and a sliding joint interface, which reduces assembly time, minimizes material thickness differences, and enhances aerodynamics by eliminating radially protruding flanges and incorporating a spring-like configuration for thermal flexibility.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional multi-piece construction is used, then structural strength and reliability are improved, but manufacturing cost and assembly time increase
Solution Approach 1:
The patent combines multiple separate components (combustor casing, outlet guide vane casing, pre-diffuser, outlet guide vanes) into a single integrated piece manufactured via additive manufacturing. This merging eliminates the need for flanges, fasteners, and multiple assembly steps, thereby reducing assembly time while maintaining structural integrity through the monolithic construction.
2Strength
If traditional multi-piece construction with flanges is used, then structural strength is improved, but aerodynamic performance deteriorates
Solution Approach 1:
By integrating the combustor casing and outlet guide vane casing into a single piece, the patent eliminates protruding flanges that would interfere with airflow. The smooth, continuous surface of the additive-manufactured component reduces aerodynamic drag and improves flow characteristics compared to traditional multi-piece constructions with external fastening elements.
3Productivity
If single-piece construction is used, then manufacturing cost and assembly time are reduced, but thermal stress resistance may worsen
Solution Approach 1:
The patent utilizes the design flexibility of additive manufacturing to incorporate internal cooling channels and optimized wall thickness distributions within the single-piece structure. These parameter changes allow heat to be dissipated more effectively throughout the component, reducing thermal gradients and associated thermal stresses despite the monolithic construction.
4Strength
If traditional manufacturing processes are used, then structural integrity is ensured, but production cost increases
Solution Approach 1:
The patent employs additive manufacturing to produce the entire assembly as a single component, eliminating the need for expensive precision machining, multiple casting operations, and extensive post-processing required by traditional methods. The additive process builds the complex geometry layer by layer, reducing material waste and manufacturing steps while maintaining structural integrity.
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 single-piece design significantly reduces manufacturing and assembly time, lowers production costs, enhances aerodynamic efficiency, and mitigates thermal stress, resulting in a more reliable and cost-effective gas turbine engine component.
Implementation Method 1
the configuration creates a spring-like section which allows for a degree of flexion within the component, which can be useful where thermal gradients can lead to material expansion, as the flexion reduces the chances of stress fractures occurring
Data Source
AI summary
A combustor casing component for a gas turbine engine which is manufactured as a single-piece. The combustor casing component has a combustor outer casing portion, an outlet guide vane outer case portion, a pre-diffuser portion, a plurality of outlet guide vanes, and an outlet guide vane inner case portion.