Fuel Injector Swirler Vane Arch Structure for Laser Deposition
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Solution Overview
Problem
Conventional manufacturing techniques for gas turbine engine fuel injectors limit the complexity of swirler vane configurations and incur high non-recurring costs due to the need for additional slave structures to prevent distortion during direct laser deposition, which are then costly to remove.
Innovation Solution
A vane structure design that allows for self-supporting construction using layers of powder metal bonded by an energy beam, with vanes extending radially between members and forming arches to enable direct laser deposition without the need for additional slave features, allowing for more complex configurations and reduced manufacturing costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If direct laser deposition is used to manufacture fuel injectors with complex swirler vane configurations, then manufacturing flexibility and complexity are improved, but additional slave structures are required which increase device complexity and manufacturing cost
Solution Approach 1:
The invention extracts and removes the problematic slave structures from the final product design. By redesigning the vane geometry to eliminate over-hanging features, the patent removes the need for temporary support structures that would otherwise be required during manufacturing, thereby reducing device complexity while maintaining manufacturing flexibility
Solution Approach 2:
Instead of adding slave structures to support over-hanging features during manufacturing, the invention inverts the approach by redesigning the vanes to be self-supporting from the start. The vanes are configured with geometry that naturally provides structural support during the layer-by-layer deposition process, eliminating the need for additional support elements
2Ease of manufacture
If conventional manufacturing techniques are used for swirler vanes, then manufacturing process is simpler, but the complexity of vane configuration is limited and non-recurring costs increase when configuration changes are needed
Solution Approach 1:
The invention changes the fundamental manufacturing parameter from conventional subtractive or casting methods to direct laser deposition additive manufacturing. This parameter change enables the creation of complex three-dimensional vane configurations with varying geometries, angles, and internal passages that would be difficult or impossible to achieve with traditional manufacturing techniques
Solution Approach 2:
The invention transitions from two-dimensional or simple three-dimensional vane designs to complex multi-dimensional configurations. The additive manufacturing process enables vanes with complex spatial relationships, curved surfaces, and varying cross-sections along multiple axes, dramatically increasing design freedom and configuration complexity
3Manufacturing precision
If slave structures are added to prevent distortion during direct laser deposition, then manufacturing precision is improved, but additional machining steps are required which increase loss of time and cost
Solution Approach 1:
The invention extracts the slave structures from the manufacturing process entirely by redesigning the vane geometry. The vanes are configured with thickness and support characteristics that prevent distortion during deposition without requiring additional support structures, thereby eliminating the subsequent machining step needed to remove these structures and reducing total manufacturing time
Solution Approach 2:
The vane design provides self-service by incorporating geometric features that inherently support themselves during the manufacturing process. The vanes are designed with adequate thickness and support from adjacent structures so that each layer supports the next during deposition, eliminating the need for external slave structures and subsequent removal operations
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
Enables the manufacture of fuel injectors with complex swirler vane geometries using direct laser deposition, reducing manufacturing costs and avoiding the need for additional machining steps, thus minimizing distortion and defects.
Implementation Method 1
layers of powder metal bonded, fused or sintered by an energy beam
Implementation Method 2
direct laser deposition (DLD)... fusing metallic powder particles together with a relatively low-power laser beam
Data Source
Figure 1
Figure 2
Figure 3~6
AI summary
A fuel injector (56) comprises a swirler (64). The swirler (64) comprises a plurality of vanes (70), a first member (72) and a second member (74). The second member (74) is arranged coaxially around the first member (72) and the vanes (70) extend radially between the first and second members (72, 74). The vanes (70) have leading edges (76) and the second member (74) has an upstream end (78). The leading edges (76) of the vanes (70) extend with radial and axial components from the first member (72) to the upstream end (78) of the second member (74) and the radially outer ends (80) of the leading edges (76) of the vanes (70) form arches (82) with the upstream end (78) of the second member (74). The arrangement of the swirler (64) enables the fuel injector (56) to be built by direct laser deposition.