Additively Manufactured Tube Array for Gas Turbine Engines
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Solution Overview
Problem
Conventional fluid conduits in gas turbine engines face challenges in fitting within tight spaces due to their circular cross-sections, which are often too large for efficient fluid flow, leading to manufacturing inefficiencies and increased likelihood of leaks, especially when multiple smaller conduits are used to accommodate space constraints.
Innovation Solution
An additively manufactured tube array with an outer wall formed by curved segments and internal divider walls that divide the primary flow passage into multiple tubes, allowing for improved fluid flow characteristics and structural rigidity, while being manufactured as a single monolithic component using advanced 3D printing techniques.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Area of stationary object
If multiple smaller conduits are used to fit within tight spaces, then space utilization is improved, but manufacturing complexity and assembly complexity increase
Solution Approach 1:
Multiple separate conduits are merged into a single integrated tube array structure. The patent combines multiple fluid transport passages into one monolithic component with a non-circular cross-section, eliminating the need to assemble multiple individual conduits and reducing assembly complexity while maintaining space utilization benefits.
Solution Approach 2:
The single tube array is segmented into multiple internal flow passages that can be independently configured. The non-circular cross-section is divided into multiple lobes or segments, each serving as a separate fluid conduit, allowing the structure to fit within tight spaces while transporting multiple fluid streams simultaneously.
2Area of stationary object
If multiple smaller conduits are used to accommodate space constraints, then space utilization is improved, but manufacturing cost increases
Solution Approach 1:
Multiple conduits are merged into a single manufactured component. The tube array is produced as one integrated piece using additive manufacturing or other suitable processes, eliminating the need to manufacture multiple separate conduits and perform multiple joining operations, thereby reducing manufacturing cost.
3Area of stationary object
If multiple smaller conduits are used to fit within tight spaces, then space utilization is improved, but reliability decreases due to increased number of joints
Solution Approach 1:
Multiple conduits are merged into a single continuous structure with internal walls separating the flow passages. This eliminates the need for external joints and connections between separate conduits, removing potential leakage points and improving reliability while maintaining the space-saving benefits of multiple flow paths.
4Strength
If conventional circular conduits are used, then structural strength is maintained, but space utilization is reduced
Solution Approach 1:
The conventional circular cross-section is replaced with a non-circular asymmetric shape that better fits the available space within the engine. The asymmetric cross-section may include flattened sides, angled walls, or irregular contours that conform to the tight spatial constraints while maintaining adequate structural strength through optimized geometry.
Solution Approach 2:
The circular cross-section is transformed into a non-circular curved shape. The patent employs smooth curved transitions and optimized contouring in the non-circular cross-section to maintain structural integrity while adapting to the available installation space, replacing the inefficient circular geometry with a space-optimized curved profile.
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 enables efficient fluid transport within tight engine spaces with reduced manufacturing costs and complexity, improved assembly processes, and enhanced reliability by integrating features like inlet and outlet manifolds, reducing the number of sub-components and joints, thus minimizing leakage and improving performance.
Implementation Method 1
depositing a layer of additive material on a bed of an additive manufacturing machine and selectively directing energy from an energy source onto the layer of additive material to fuse a portion of the additive material
Data Source
AI summary
A tube array and a method for additively manufacturing the tube array are provided. The tube array includes an outer wall formed by a plurality of curved segments and defining a primary flow passage. A plurality of divider walls are positioned within the primary flow passage to divide the primary flow passage into a plurality of tubes, each of the plurality of tubes being defined at least in part by one of the plurality of curved segments and two of the plurality of divider walls. Integrally formed inlet and outlet manifolds provide fluid communication between the tube array and an array inlet and outlet.