METHOD OF MANUFACTURING A UNITARY SWIRLER

• US 20090255119A1
• Filed: 08/29/2008
• Published: 10/15/2009
• Est. Priority Date: 04/11/2008
• Status: Abandoned Application

• Current Assignee: General Electric Company
• Original Assignee: General Electric Company
• Inventors: Benjamin, Michael A., McMasters, Marie Ann, Mancini, Alfred
• Application Number:
  US12/200,960
• Publication Number:
  US 20090255119A1
• Time in Patent Office: Days
• US Class Current: 29/889.200
• CPC Class Codes: B22F 2007/068 repairing articles
• CPC Class Codes: B23P 2700/13 Parts of turbine combustion chambers
• CPC Class Codes: B23P 6/005 using only replacement pieces of a particular form
• CPC Class Codes: B23P 6/007 using only additive methods, e.g. build-up welding
• CPC Class Codes: B33Y 80/00 Products made by additive manufacturing
• CPC Class Codes: F23D 2213/00 Burner manufacture specifications
• CPC Class Codes: F23D 2900/00018 Means for protecting parts of the burner, e.g. ceramic lining outside of the flame tube
• CPC Class Codes: F23D 2900/14701 Swirling means inside the mixing tube or chamber to improve premixing
• CPC Class Codes: F23R 2900/00018 Manufacturing combustion chamber liners or subparts
• CPC Class Codes: F23R 3/14 by using swirl vanes
• CPC Class Codes: F23R 3/28 characterised by the fuel supply burners F23D
• CPC Class Codes: F23R 3/283 Attaching or cooling of fuel injecting means including supports for fuel injectors, stems, or lances
• CPC Class Codes: F23R 3/286 having fuel-air premixing devices F23R3/30 takes precedence
• CPC Class Codes: F23R 3/343 Pilot flames, i.e. fuel nozzles or injectors using only a very small proportion of the total fuel to insure continuous combustion ignition in gas-turbine plants F02C7/264; pilot flame igniters F23Q9/00
• CPC Class Codes: Y02E 30/30 Nuclear fission reactors
• CPC Class Codes: Y02P 10/25 Process efficiency
• CPC Class Codes: Y02T 50/60 Efficient propulsion technologies, e.g. for aircraft
• CPC Class Codes: Y10T 137/265 Plural outflows
• CPC Class Codes: Y10T 29/49318 Repairing or disassembling
• CPC Class Codes: Y10T 29/4932 Turbomachine making
• CPC Class Codes: Y10T 29/49746 : by applying fluent material, e.g., coating, casting

Abstract

A method for fabricating a unitary swirler is disclosed, the method comprising the steps of determining three-dimensional information of the unitary swirler having a plurality of vanes arranged in a circumferential direction on a body around a swirler axis and a wall extending between a rim and a portion of the body, converting the three-dimensional information into a plurality of slices that each define a cross-sectional layer of the unitary swirler, and successively forming each layer of the unitary swirler by fusing a metallic powder using laser energy. Exemplary embodiments are disclosed, showing a unitary swirler comprising a plurality of vanes extending from a hub having a unitary construction wherein unitary swirler is made by using a rapid manufacturing process. In one aspect of the invention, the rapid manufacturing process is a laser sintering process.

Claims

1. A method for fabricating a unitary swirler, said method comprising the steps of:

determining three-dimensional information of the unitary swirler having a plurality of vanes arranged in a circumferential direction on a body around a swirler axis and a wall extending between a rim and a portion of the body;

converting the three-dimensional information into a plurality of slices that each define a cross-sectional layer of the unitary swirler; and

successively forming each layer of the unitary swirler by fusing a metallic powder using laser energy.

2. A method in accordance with claim 1 wherein determining three-dimensional information of the unitary swirler further comprises determining a three-dimensional model of the unitary swirler.

3. A method in accordance with claim 1 wherein successively forming each layer of the unitary swirler by fusing a metallic powder using laser energy further comprises fusing a powder comprising at least one of cobalt chromium, HS188 and INCO 625.

4. A method in accordance with claim 1 wherein successively forming each layer of the unitary swirler by fusing a metallic powder using laser energy further comprises fusing a metallic powder that has a particle size between about 10 microns and about 75 microns.

5. A method in accordance with claim 4 wherein successively forming each layer of the unitary swirler by fusing a metallic powder using laser energy further comprises fusing a metallic powder that has a particle size between about 15 microns and about 30 microns.

6. A method in accordance with claim 1 wherein determining three-dimensional information of the unitary swirler further comprises determining a three-dimensional model of the unitary swirler having a gap located at least partially within the body.

7. A method in accordance with claim 1 wherein determining three-dimensional information of the unitary swirler further comprises determining a three-dimensional model of the unitary swirler having at least one vane that has a geometry that is different from another vane.

8. A method in accordance with claim 1 wherein determining three-dimensional information of the unitary swirler further comprises determining a three-dimensional model of the unitary swirler having an adaptor having a passage that is configured to direct a flow of air towards at least some of the plurality of vanes.

9. A method in accordance with claim 8 wherein the passage is formed by an arcuate wall extending from a portion of the body.

10. A method in accordance with claim 8 wherein the adaptor has a groove capable of receiving a brazing material.

11. A unitary swirler comprising a plurality of vanes extending from a hub arranged in a circumferential direction around an axis on a body having a unitary construction wherein unitary swirler is made by using a rapid manufacturing process.

12. A unitary swirler according to claim 11 wherein the rapid manufacturing process is a laser sintering process.

13. A unitary swirler according to claim 11 wherein the rapid manufacturing process is DMLS.

14. A unitary swirler according to claim 11 further comprising a rim coaxial with the axis.

15. A unitary swirler according to claim 14 further comprising a wall extending between a portion of the rim and a portion of the hub.

16. A unitary swirler according to claim 11 wherein each vane has substantially the same geometry.

17. A unitary swirler according to claim 11 wherein at least one vane has a geometry that is different from another vane.

18. A unitary swirler according to claim 11 wherein the body has an insulation gap located at least partially within the body.

19. A unitary swirler according to claim 11 further comprising an adaptor having a passage that is configured to direct a flow of air towards at least some of the plurality of vanes.

20. A unitary swirler according to claim 19 wherein the passage is formed by an arcuate wall extending from a portion of body.