Turbulator Fabrication via Additive Brazing
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional turbulator fabrication methods for gas turbine combustor liners are time-consuming and material-intensive, resulting in long processing times and significant material waste.
Innovation Solution
An additive method involving the disposition of an elongate flexible member in tension onto a liner body, followed by the dispensation of braze paste and a brazing process to attach the member, significantly reducing material usage and processing time by forming a braze joint that acts as a turbulator.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional machining process is used to form turbulator, then desired shape and size can be achieved, but processing time increases to 10 hours and material waste increases by 30%
Solution Approach 1:
Instead of removing material through machining to create the turbulator, the invention inverts the approach by additively disposing an elongate flexible member onto the liner body and using brazing to form the turbulator structure. This inversion from subtractive to additive manufacturing eliminates the 10-hour machining process while achieving the desired turbulator geometry through material deposition and joining.
Solution Approach 2:
The invention replaces the mechanical machining system with a thermal brazing system. Instead of using cutting tools to mechanically remove material, the process uses braze paste and thermal energy to join the flexible member to the liner body, forming the turbulator structure through controlled heating and metallurgical bonding.
2Manufacturing precision
If conventional machining process is used to form turbulator, then desired shape and size can be achieved, but raw material usage increases by 30%
Solution Approach 1:
The invention inverts the material removal approach by using additive disposition of the flexible member followed by brazing. This eliminates the 30% material waste associated with machining by only using the exact amount of material needed for the turbulator structure, joining it directly to the liner body through the braze joint.
3Productivity
If additive method with braze paste is used, then processing time reduces to 1 hour and material usage reduces by 30%, but process complexity increases due to brazing requirements
Solution Approach 1:
The invention introduces braze paste as an intermediary material that simplifies the joining process. The braze paste acts as a flux and filler metal combination that enables reliable bonding between the flexible member and liner body at lower temperatures than direct welding, reducing the overall process complexity despite the additive manufacturing approach.
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 method reduces raw material usage by 30% and processing time from 10 hours to 1 hour, minimizing waste and enhancing efficiency in turbulator fabrication.
Implementation Method 1
conducting a brazing process with respect to the braze paste to attach the elongate flexible member to the liner body
Data Source
AI summary
A method of turbulator fabrication is provided and includes additively disposing an elongate flexible member in tension onto a liner body, dispensing braze paste at an elongate flexible member-liner body interface and conducting a brazing process with respect to the braze paste to attach the elongate flexible member to the liner body.