Swaged Liquid Fuel Injection Spoke for Gas Turbine Engines
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Solution Overview
Problem
Current liquid fuel injection spokes in gas turbine engines face issues with fuel leakage and unreliable engagement with the manifold, leading to uneven fuel burning and temperature distributions, due to lack of a strong material bond and precise manufacturing requirements.
Innovation Solution
A liquid fuel injection spoke design with a deformable head and stem, utilizing molecular diffusion and swagers to form a secure joint with the manifold, preventing leakage and stress cracking, while maintaining an unobstructed fluid passageway.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional engagement methods are used between spokes and manifold, then manufacturing is simpler, but fuel leakage occurs and engagement reliability is poor
Solution Approach 1:
The patent replaces traditional mechanical engagement methods (such as threaded connections or interference fits) with a diffusion bonding process. The spoke and manifold are brought into intimate contact and bonded at the molecular level through diffusion, eliminating the need for separate fasteners or complex mechanical interlocking features. This substitution achieves superior engagement reliability while simplifying the overall manufacturing process by reducing the number of assembly steps and components.
Solution Approach 2:
The patent utilizes controlled changes in temperature and pressure parameters during the diffusion bonding process. By heating the assembly to elevated temperatures and applying controlled pressure, the molecular diffusion rate between the spoke and manifold is enhanced, creating a strong metallurgical bond. These parameter changes enable reliable engagement while maintaining manufacturing simplicity, as the bonding process can be performed in a single step without complex tooling.
2Strength
If conventional joining methods are used, then manufacturing cost is lower, but stress cracking occurs and bond strength is insufficient
Solution Approach 1:
The patent replaces conventional joining methods (welding, brazing, or mechanical fastening) with diffusion bonding. This process creates a metallurgical bond at the molecular level by facilitating atomic interdiffusion between the spoke and manifold materials under controlled temperature and pressure. The resulting bond strength exceeds that of traditional methods while avoiding stress concentrations and heat-affected zones that lead to cracking, all within a relatively simple single-step manufacturing process.
3Reliability
If tight tolerances are applied for precise engagement, then leakage is prevented, but manufacturing precision requirements increase costs
Solution Approach 1:
The patent replaces precision mechanical fitting with diffusion bonding. Instead of relying on tight dimensional tolerances to prevent leakage, the process creates a molecular-level bond between the spoke and manifold that inherently seals the interface. This substitution eliminates the need for high-precision machining and tight tolerance control, reducing manufacturing costs while ensuring complete leakage prevention through the metallurgical bond itself.
4Strength
If deformation is applied to form the joint, then material bonding is achieved, but deformation control must be precise to avoid defects
Solution Approach 1:
The patent employs controlled changes in temperature and pressure parameters to facilitate diffusion bonding. By heating the assembly to elevated temperatures, the atomic diffusion rate is dramatically increased, enabling strong material bonding at relatively low pressures. This parameter control approach achieves reliable material bonds while avoiding the need for precise deformation control, as the bonding occurs through thermal activation rather than mechanical deformation. The process parameters can be easily monitored and controlled within standard manufacturing capabilities.
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 effectively prevents fuel leakage and reduces stress cracking, forming a strong bond between the spoke and manifold without obstructing the fluid passageway, enhancing combustion efficiency and reducing manufacturing costs.
Implementation Method 1
materially bonding the liquid fuel injection spoke to the manifold via molecular diffusion
Data Source
AI summary
A liquid fuel injection spoke for a gas turbine engine. The liquid fuel injection spoke may include an inlet end and an outlet end. The liquid fuel injection spoke may further include a head located at the inlet end and a stem extending along a longitudinal axis from the head to the outlet end. The stem may define a fluid passageway therein. The head may include a cavity with an inner wall. The inner wall may include an annular protrusion.