6/22/2017 PatentWO2015050987A1AdditivemanufacturedfuelnozzlecoreforagasturbineengineGooglePatents

Signin

Patents English French Findpriorart Discussthisapplication

Additivemanufacturedfuelnozzlecorefora Publicationnumber WO2015050987A1

gasturbineengine Publicationtype Application
Applicationnumber PCT/US2014/058617
WO2015050987A1 Publicationdate Apr9,2015
Filingdate Oct1,2014
ABSTRACT Prioritydate Oct4,2013
Alsopublishedas EP3052784A1,EP3052784A4,
Amethodofmanufacturingafuelcomponentforagasturbineenginecombustor
US20160236271
includesadditivemanufacturingasacrificialcoreandmanufacturingafuel
Inventors JinquanXu
componentbodyatleastpartiallyaroundthesacrificialcore.Thesacrificialcore
Applicant UnitedTechnologiesCorporation
isatleastpartiallyremovedtoatleastpartiallydefineaninternalgeometryofthe
fuelcomponent.Anadditivelymanufacturedsacrificialcoreforafuelcomponent ExportCitation BiBTeX,EndNote,RefMan
ofagasturbineenginecombustorincludesafirststructureandasecond PatentCitations(5),NonPatentCitations(1),Referencedby(2),
Classifications(15),LegalEvents(3)
structure.Thefirststructureatleastpartiallydefinesafirstpassageofthefuel
component.Thesecondstructureatleastpartiallydefinesasecondpassageof ExternalLinks:Patentscope,Espacenet
thefuelcomponent.Thesecondstructureatleastpartiallysurroundsthefirst
structure.

DESCRIPTION(OCRtextmaycontainerrors) CLAIMS(OCRtextmaycontainerrors)

ADDITIVEMANUFACTUREDFUELNOZZLECORE CLAIMSWhatisclaimedis:

FORAGASTURBINEENGINE
CROSSREFERENCETORELATEDAPPLICATION[0001]Thisapplication
claimsprioritytoU.S.PatentAppln.SerialNo.61/886,980filedOctober4,2013,
whichisherebyincorporatedhereinbyreferenceinitsentirety.
BACKGROUND
[0002]Thepresentdisclosurerelatestoafuelnozzleassemblyforagasturbine
engineand,moreparticularly,tothemanufacturethereof.
1.Amethodofmanufacturingafuelcomponentforagasturbineengine
combustor,themethodcomprising:
additivemanufacturingasacrificialcore
manufacturingafuelcomponentbodyatleastpartiallyaroundthesacrificial
coreandatleastpartiallyremovingthesacrificialcoretoatleastpartially
defineaninternalgeometryofthefuelcomponent.

[0003]Gasturbineenginestypicallyincludeacompressorsectiontopressurize 2.Themethodasrecitedinclaim1,furthercomprisingadditivemanufacturing
airflow,acombustorsectiontoburnahydrocarbonfuelinthepresenceofthe thesacrificialcoreofarefractorymetalalloy.
pressurizedair,andaturbinesectiontoextractenergyfromtheresultant
combustiongases.
3.Themethodasrecitedinclaim1,furthercomprisingadditivemanufacturing
[0004]Thecombustorsectionincludesamultipleofcircumferentiallydistributed thesacrificialcoreofaceramicmaterial.
fuelnozzlesandswirlersincommunicationwithacombustionchambertosupply
fueltomixwiththepressurizedairflow.Althougheffective,thefuelnozzlesand
swirlersarerelativelycomplicatedtomanufacture.
4.Themethodasrecitedinclaim1,furthercomprisingadditivemanufacturing

SUMMARY thesacrificialcoreofahybridmaterial.

[0005]Amethodofmanufacturingafuelcomponentforagasturbineengine
combustor,accordingtoonedisclosednonlimitingembodimentofthepresent
disclosure,includesadditivemanufacturingasacrificialcoremanufacturinga
fuelcomponentbodyatleastpartiallyaroundthesacrificialcoreandatleast
partiallyremovingthesacrificialcoretoatleastpartiallydefineaninternal
geometryofthefuelcomponent.[0006]Inafurtherembodimentofthepresent
disclosure,themethodincludesadditivemanufacturingthesacrificialcoreofa
refractorymetalalloy.
5.Themethodasrecitedinclaim1,furthercomprisingadditivemanufacturingan
interfacestructurethatatleastpartiallysurroundsthesacrificialcore.
6.Themethodasrecitedinclaim1,furthercomprisingadditivemanufacturingan
interfacestructureofthesacrificialcorethatisoutsidetheinternalgeometryof
thefuelcomponentbodyduringthemanufacturingofthefuelcomponentbody.

[0007]Inafurtherembodimentofanyoftheforegoingembodimentsofthe
presentdisclosure,themethodincludesadditivemanufacturingthesacrificial
coreofaceramicmaterial.
TrythenewGooglePatents,withmachineclassifiedGoogleScholarresults,andJapaneseandSouthKoreanpatents.

https://www.google.com/patents/WO2015050987A1?cl=en 1/6
6/22/2017 PatentWO2015050987A1AdditivemanufacturedfuelnozzlecoreforagasturbineengineGooglePatents
[0008]Inafurtherembodimentofanyoftheforegoingembodimentsofthe 7.Themethodasrecitedinclaim1,furthercomprisingadditivemanufacturinga
presentdisclosure,themethodincludesadditivemanufacturingthesacrificial connectionofthesacrificialcorethatisinsidetheinternalgeometryofthefuel
coreofahybridmaterial. componentbodyduringthemanufacturingofthefuelcomponentbody.

[0009]Inafurtherembodimentofanyoftheforegoingembodimentsofthe
presentdisclosure,themethodincludesadditivemanufacturinganinterface
8.Themethodasrecitedinclaim1,furthercomprisingadditivemanufacturinga
structurethatatleastpartiallysurroundsthesacrificialcore.
firststructureandasecondstructure,thefirststructureatleastpartiallydefining
[0010]Inafurtherembodimentofanyoftheforegoingembodimentsofthe afirstpassageoftheinternalgeometryandthesecondstructureatleastpartially
presentdisclosure,themethodincludesadditivemanufacturinganinterface definingasecondpassageoftheinternalgeometry.
structureofthesacrificialcorethatisoutsidetheinternalgeometryofthefuel
componentbodyduringthemanufacturingofthefuelcomponentbody.
9.Themethodasrecitedinclaim8,furthercomprisingadditivemanufacturingan
[0011]Inafurtherembodimentofanyoftheforegoingembodimentsofthe interfacestructurebetweenthefirststructureandthesecondstructurethatis
presentdisclosure,themethodincludesadditivemanufacturingaconnectionof outsidetheinternalgeometryofthefuelcomponentbodyduringthe
thesacrificialcorethatisinsidetheinternalgeometryofthefuelcomponentbody manufacturingofthefuelcomponentbody.
duringthemanufacturingofthefuelcomponentbody.

[0012]Inafurtherembodimentofanyoftheforegoingembodimentsofthe
presentdisclosure,themethodincludesadditivemanufacturingafirststructure
andasecondstructure.Thefirststructureatleastpartiallydefinesafirst
passageoftheinternalgeometry.Thesecondstructureatleastpartiallydefines
asecondpassageoftheinternalgeometry.
10.Themethodasrecitedinclaim8,furthercomprisingadditivemanufacturinga
connectionbetweenthefirststructureandthesecondstructurethatiswithinthe
internalgeometryofthefuelcomponentbodyduringthemanufacturingofthefuel
componentbody.

[0013]Inafurtherembodimentofanyoftheforegoingembodimentsofthe
presentdisclosure,themethodincludesadditivemanufacturinganinterface 11.Anadditivelymanufacturedsacrificialcoreforafuelcomponentofagas
structurebetweenthefirststructureandthesecondstructurethatisoutsidethe turbineenginecombustor,comprising:
internalgeometryofthefuelcomponentbodyduringthemanufacturingofthefuel
componentbody. afirststructurethatatleastpartiallydefinesafirstpassageofthefuel
componentandasecondstructurethatatleastpartiallydefinesasecond
[0014]Inafurtherembodimentofanyoftheforegoingembodimentsofthe passageofthefuelcomponent,thesecondstructureatleastpartially
presentdisclosure,themethodincludesadditivemanufacturingaconnection surroundingthefirststructure.
betweenthefirststructureandthesecondstructurethatiswithintheinternal
geometryofthefuelcomponentbodyduringthemanufacturingofthefuel
componentbody. 12.Theadditivelymanufacturedsacrificialcoreasrecitedinclaim11,wherein
thesacrificialcoreismanufacturedofarefractorymetalalloy.
[0015]Anadditivelymanufacturedsacrificialcoreforafuelcomponentofagas
turbineenginecombustor,accordingtoanotherdisclosednonlimiting
embodimentofthepresentdisclosure,includesafirststructurethatatleast
partiallydefinesafirstpassageofthefuelcomponentandasecondstructure 13.Theadditivelymanufacturedsacrificialcoreasrecitedinclaim11,wherein
thatatleastpartiallydefinesasecondpassageofthefuelcomponent.The thesacrificialcoreismanufacturedofaceramicmaterial.
secondstructureatleastpartiallysurroundsthefirststructure.

[0016]Inafurtherembodimentofanyoftheforegoingembodimentsofthe 14.Theadditivelymanufacturedsacrificialcoreasrecitedinclaim11,wherein
presentdisclosure,thesacrificialcoreismanufacturedofarefractorymetalalloy. thesacrificialcoreismanufacturedofahybridmaterial.

[0017]Inafurtherembodimentofanyoftheforegoingembodimentsofthe
presentdisclosure,thesacrificialcoreismanufacturedofaceramicmaterial.
15.Theadditivelymanufacturedsacrificialcoreasrecitedinclaim11,wherein
[0018]Inafurtherembodimentofanyoftheforegoingembodimentsofthe thefuelcomponentisafuelnozzle.
presentdisclosure,thesacrificialcoreismanufacturedofahybridmaterial.

[0019]Inafurtherembodimentofanyoftheforegoingembodimentsofthe
16.Theadditivelymanufacturedsacrificialcoreasrecitedinclaim15,wherein
presentdisclosure,thefuelcomponentisafuelnozzle.
thefirststructureisdefinedatleastpartiallyalongacentralaxis,thesecond
[0020]Inafurtherembodimentofanyoftheforegoingembodimentsofthe structuredefinedatleastpartiallyaroundthefirststructure.
presentdisclosure,thefirststructureisdefinedatleastpartiallyalongacentral
axis.Thesecondstructuredefinedatleastpartiallyaroundthefirststructure.
17.Theadditivelymanufacturedsacrificialcoreasrecitedinclaim16,wherein
[0021]Inafurtherembodimentofanyoftheforegoingembodimentsofthe
thesecondstructureatleastpartiallydefinesahelicalmember.
presentdisclosure,thesecondstructureatleastpartiallydefinesahelical
member.[0022]Inafurtherembodimentofanyoftheforegoingembodimentsof
thepresentdisclosure,athirdstructureisincludedanddefinedatleastpartially
18.Theadditivelymanufacturedsacrificialcoreasrecitedinclaim16,further
aroundthesecondstructure.
comprisingathirdstructureisdefinedatleastpartiallyaroundthesecond
structure.
TrythenewGooglePatents,withmachineclassifiedGoogleScholarresults,andJapaneseandSouthKoreanpatents.

https://www.google.com/patents/WO2015050987A1?cl=en 2/6
6/22/2017 PatentWO2015050987A1AdditivemanufacturedfuelnozzlecoreforagasturbineengineGooglePatents
[0023]Inafurtherembodimentofanyoftheforegoingembodimentsofthe
presentdisclosure,afourthstructureisincludedanddefinedatleastpartially 19.Theadditivelymanufacturedsacrificialcoreasrecitedinclaim18,further
aroundthethirdstructure.Thefourthstructuredefinesaninnersurfaceofastrut comprisingafourthstructuredefinedatleastpartiallyaroundthethirdstructure,
ofthefuelnozzle. thefourthstructuredefininganinnersurfaceofastrutofthefuelnozzle.

[0024]Inafurtherembodimentofanyoftheforegoingembodimentsofthe
presentdisclosure,aninterfacestructureisincludedbetweenthefirststructure
20.Theadditivelymanufacturedsacrificialcoreasrecitedinclaim16,further
andthesecondstructure.Theinterfacestructureislocatedoutsidethefirst
comprisinganinterfacestructurebetweenthefirststructureandthesecond
passageandthesecondpassageofthefuelnozzle.
structure,whereintheinterfacestructureislocatedoutsidethefirstpassageand
[0025]Theforegoingfeaturesandelementsmaybecombinedinvarious thesecondpassageofthefuelnozzle.
combinationswithoutexclusivity,unlessexpresslyindicatedotherwise.These
featuresandelementsaswellastheoperationthereofwillbecomemore
apparentinlightofthefollowingdescriptionandtheaccompanyingdrawings.Itshouldbeunderstood,however,the
followingdescriptionanddrawingsareintendedtobeexemplaryinnatureandnonlimiting.

BRIEFDESCRIPTIONOFTHEDRAWINGS

[0026]Variousfeatureswillbecomeapparenttothoseskilledintheartfromthefollowingdetaileddescriptionofthe
disclosednonlimitingembodiment.Thedrawingsthataccompanythedetaileddescriptioncanbebrieflydescribedas
follows:

[0027]FIG.1isaschematiccrosssectionofanexamplegasturbineenginearchitecture

[0028]FIG.2isanexpandedlongitudinalschematicsectionalviewofanexamplecombustorsection

[0029]FIG.3isanisometricviewofafuelinjector[0030]FIG.4isasectionalviewofthefuelinjectorofFIG.3

[0031]FIG.5isanexpandedlateralsectionalviewofafuelnozzlealongline55in

FIG.4

[0032]FIG.6isaperspectivesectionalviewofasacrificialcoreforthefuelnozzleaccordingtoonedisclosednonlimiting
embodiment

[0033]FIG.7isaperspectiveviewofasacrificialcoreforthefuelnozzleaccordingtoanotherdisclosednonlimiting
embodimentand

[0034]FIG.8isaflowchartshowinganexemplaryembodimentofamethodforfabricatingafuelcomponentbody.

DETAILEDDESCRIPTION

[0035]FIG.1schematicallyillustratesagasturbineengine20.Thegasturbineengine20isdisclosedhereinasatwospool
turbofanthatgenerallyincludesafansection22,acompressorsection24,acombustorsection26andaturbinesection
28.Thefansection22drivesairalongabypassflowpathandintothecompressorsection24.Thecompressorsection24
drivesairalongacoreflowpathforcompressionandcommunicationintothecombustorsection26,whichthenexpandsand
directstheairthroughtheturbinesection28.Althoughdepictedasaturbofaninthedisclosednonlimitingembodiment,it
shouldbeunderstoodthattheconceptsdescribedhereinarenotlimitedtousewithturbofansastheteachingsmaybe
appliedtoothertypesofturbineenginessuchasalowbypassaugmentedturbofan,turbojets,turboshafts,andthreespool
(plusfan)turbofanswithanintermediatespool.Stillotherenginearchitecturesarelocatedwithinanenclosuretypicalofan
industrialgasturbine(IGT).

[0036]WithreferencetoFIG.2,thecombustorsection26generallyincludesacombustor56withanoutercombustorwall
assembly60,aninnercombustorwallassembly62andadiffusercasemodule64.Theoutercombustorwallassembly60
andtheinnercombustorwallassembly62arespacedapartsuchthatacombustionchamber66isdefinedtherebetween.
Thecombustionchamber66maybegenerallyannularinshape.

[0037]Theoutercombustorlinerassembly60isspacedradiallyinwardfromanouterdiffusercase64Aofthediffusercase
module64todefineanouterannularplenum76.Theinnercombustorlinerassembly62isspacedradiallyoutwardfroman
innerdiffusercase64Bofthediffusercasemodule64todefineaninnerannularplenum78.Itshouldbeunderstoodthat
althoughaparticularcombustorisillustrated,othercombustortypestoincludebutnotbelimitedtoacancombustor
architectureaswellasvariouscombustorlinerarrangementswillalsobenefitherefrom.

[0038]Thecombustorwallassemblies60,62containthecombustionproductsfordirectiontowardtheturbinesection28.
Eachcombustorwallassembly60,62generallyincludesarespectivesupportshell68,70whichsupportsoneormoreliner
panels72,74.Eachofthelinerpanels72,74maybegenerallyrectilinearandmanufacturedof,forexample,anickelbased
superalloy,ceramicorotherhightemperatureresistantmaterialandarearrangedtoformalinerarray.Inonedisclosednon
TrythenewGooglePatents,withmachineclassifiedGoogleScholarresults,andJapaneseandSouthKoreanpatents.

https://www.google.com/patents/WO2015050987A1?cl=en 3/6
6/22/2017 PatentWO2015050987A1AdditivemanufacturedfuelnozzlecoreforagasturbineengineGooglePatents
limitingembodiment,thelinerarrayincludesamultipleofforwardlinerpanels72Aandamultipleofaftlinerpanels72Bthat
arecircumferentiallystaggeredtolinetheoutershell68.Amultipleofforwardlinerpanels74Aandamultipleofaftliner
panels74Barecircumferentiallystaggeredtolinetheinnershell70.

[0039]Thecombustor56furtherincludesaforwardassembly80immediatelydownstreamofthecompressorsection24to
receivecompressedairflowtherefrom.Theforwardassembly80generallyincludesanannularhood82andabulkhead
assembly84whichlocateamultipleoffuelcomponentssuchasfuelinjectors86(oneshown)andamultipleofswirlers90
(oneshown).Eachoftheswirlers90ismountedwithinanopening92ofthebulkheadassembly84tobecircumferentially
alignedwithoneofamultipleofannularhoodports94.Eachbulkheadassembly84generallyincludesabulkheadsupport
shell96securedtothecombustorwallassembly60,62,andamultipleofcircumferentiallydistributedbulkheadlinerpanels
98securedtothebulkheadsupportshell96.

[0040]Theannularhood82extendsradiallybetween,andissecuredto,theforwardmostendsofthecombustorwall
assemblies60,62.Theannularhood82formsthemultipleofcircumferentiallydistributedhoodports94thataccommodate
therespectivefuelinjector86andintroduceairintotheforwardendofthecombustionchamber66.Eachfuelinjector86
maybesecuredtothediffusercasemodule64andprojectthroughoneofthehoodports94andtherespectiveswirler90.

[0041]Theforwardassembly80introducescorecombustionairintotheforwardsectionofthecombustionchamber66while
theremainderenterstheouterannularplenum76andtheinnerannularplenum78.Themultipleoffuelinjectors86and
adjacentstructuregenerateablendedfuelairmixturethatsupportsstablecombustioninthecombustionchamber66.

[0042]Oppositetheforwardassembly80,theouterandinnersupportshells68,70aremountedtoafirstrowofNozzle
GuideVanes(NGVs)28A.TheNGVs28Aarestaticenginecomponentswhichdirectthecombustiongasesontotheturbine
bladesintheturbinesection28tofacilitatetheconversionofpressureenergyintokineticenergy.Thecombustiongasesare
alsoacceleratedbytheNGVs28Abecauseoftheirconvergentshapeandaretypicallygivena"spin"ora"swirl"inthe
directionofturbinerotation.

[0043]WithreferencetoFIG.3,eachofthemultipleoffuelinjectors86illustratedinFIG.3asaduplexfuelnozzlemay
includeafirstinlet100,asecondinlet102,asupport104,amountflange106andanozzletip108.Inanotherdisclosed
nonlimitingembodiment,thefirstinlet100mayreceiveafirstfluidasaliquid,suchasJetA,diesel,JP8,waterand
combinationsthereofandthesecondinlet102mayreceiveasecondfluidasagassuchasanaturalgas.

[0044]WithreferencetoFIG.4,thefirstinlet100communicateswiththenozzletip108throughafirstpassage120andthe
secondinlet102communicateswiththenozzletip108throughasecondpassage122.Inonedisclosednonlimiting
embodiment,atube124(alsoshowninFIG.5)alongacentralaxisFofthefuelinjector86definesthefirstpassage120
whilethesecondpassage122isdefinedbyafirstwall126(alsoshowninFIG.5)aroundthetube124andwithinthe
support104.Inthisdisclosednonlimitingembodiment,ahelicalmember128islocatedwithinthesecondpassage122.A
secondwall130furtherdefinesaninnervolume132aroundthefirstwall126andanoutervolume134betweenthesecond
wall130andthesupport104.Thesecondwall130,forexample,operatesasaheatshieldbetweenthepassages120,122
andthesupport104.Itshouldbeappreciatedthatvariousstructures,passageandvolumeswillalternatelybenefitherefrom.

[0045]Thepassages120,122andvolumes132,134define,asillustratedinthisdisclosednonlimitingembodiment,an
internalgeometry136ofthefuelinjector86.Asdefinedherein,passages120,122communicatebetweentherespective
inlets100,102andthetipnozzle108,whilevolumes132,134maybesealedfromoneorboth.Thepassages120,122and
volumes132,134maybeconnectedbyand/orcontainvarioustransversestructure138(seealsoFIG.5)atoneormore
longitudinalpositionstoproviderelativestructuralsupport,e.g.,strutsand/orflowcontrol,e.g.,helicalmember128.

[0046]WithreferencetoFIG.6,asacrificialcore140definestheinternalgeometry136ofafuelcomponentbody142(see
FIGS.4and5).Thatis,thefuelcomponentbody142generallyincludesthefirstinlet100,thesecondinlet102,thesupport
104,themountflange106andthenozzletip108withtheinternalgeometry136thereofformedbythesacrificialcore140.In
thisdisclosednonlimitingembodiment,thefuelcomponentbody142isgenerallyrectilinearorcircularincrosssection,
howeverothercrosssectionswillalsobenefitherefromanditshouldbeappreciatedthattheexampleinternalgeometry136
isillustrativeonly.Furthermore,althoughafuelnozzlebodyisillustratedinthedisclosednonlimitingembodimentoffuel
componentbody142,othercomponentsincommunicationwiththecombustionchamber66suchastheswirler90andother
fuelaircomponentwithrelativelycomplexinternalgeometry136willalsobenefitherefrom.

[0047]Thesacrificialcore140generallyincludesafirststructure144thatdefinesthefirstpassage120,asecondstructure
146thatdefinesthesecondpassage122,athirdstructure148thatdefinestheinnervolume132andafourthstructure150
thatdefinestheoutervolume134.Thefirststructure144isgenerallysurroundedbythesecondstructure146thatis
generallysurroundedbythethirdstructure148whichisgenerallysurroundedbythefourthstructure150.Thatis,the
structures144,146,148,150aregenerallyconcentricbutmayincludeoneormoreconnections152(illustratedsomewhat
schematically)therebetweentoprovide,inthisdisclosednonlimitingembodiment,aselfsupportingsacrificialcore140.The
variousconnections152are,forexample,thenegativeofthetransversestructure138.Thatis,thesacrificialcore140isthe
positivestructureoftheinternalgeometry136suchthatnegativesofthesacrificialcore140formstructureswithinor
TrythenewGooglePatents,withmachineclassifiedGoogleScholarresults,andJapaneseandSouthKoreanpatents.
betweenthepassages120,122,thevolumes132,134suchasconnections152,helicalmember128,etc.

https://www.google.com/patents/WO2015050987A1?cl=en 4/6
6/22/2017 PatentWO2015050987A1AdditivemanufacturedfuelnozzlecoreforagasturbineengineGooglePatents
[0048]Theadditivemanufacturedsacrificialcore140mayalternativelyoradditionallyincludeaninterfacestructure154(see
FIG.7)thatdefinesaconnectionbetweenthefirststructure144andthesecondstructure146formedoutsideofthe
respectiveinlets100,102.Thatis,theinterfacestructure154essentiallyconnectsthepassages120,122,andformsno
partofthefuelcomponentbody142oncemanufactured.Theinterfacestructure154facilitatesstructuralsupportofthe
sacrificialcore140atlocationsbetweenthestructure144,146,i.e.,passages120,122,whichmaynototherwisebe
connected,e.g,wherenotransversestructure138isprovidedtherebetween.Thatis,theinterfacestructure154maybe
utilizedtoprovideaselfsupportingadditivemanufacturedsacrificialcore140.Alternatively,inanotherdisclosednonlimiting
embodiment,theinterfacestructure154maybeashellthatcontainsthesacrificialcore140.Thatis,thesacrificialcore140
isretainedwithintheinterfacestructure154.

[0049]Thesacrificialcore140maybemanufacturedwitharapidmanufacturingprocessessuchasDirectMetalLaser
Sintering(DMLS),LaserNetShapeManufacturing(LNSM),ElectronBeamMelting(EBM)and/orotheradditive
manufacturingprocesses.Thesacrificialcore140facilitatesmanufactureoftherelativelycomplexinternalgeometry136to
minimizeassemblydetailsandmulticomponentconstruction.

[0050]WithreferencetoFIG.8,aflowchartillustratesonedisclosednonlimitingembodimentofamethod200for
fabricatingthefuelcomponentbody142.Themethodinitiallyincludestheadditivemanufactureofthesacrificialcore140
using,forexampleonly,DirectMetalLaserSintering(DMLS)(Step202).DMLSisamanufacturingprocessthatfabricates
componentsusingthreedimensionalinformation,forexampleathreedimensionalcomputermodel,ofthesacrificialcore
140.Thethreedimensionalinformationisconvertedintoapluralityofslices,eachslicedefiningacrosssectionofthe
componentforapredeterminedheightoftheslice.Theadditivemanufacturedsacrificialcore140isthen"grown"sliceby
slice,orlayerbylayer,untilfinished.Eachlayerhasasizebetweenabout0.00050.001inches(0.01270.0254mm).

[0051]Inonedisclosednonlimitingembodiment,thesacrificialcore140isadditivemanufacturedfromarefractorymetal
alloypowdersuchasMO,NB,TA,W,orothersuitablerefractorymetalormixturethereof,andoptionally,aprotective
coating.Examplerefractorymetalalloysmayincludeatleast50%ormorebyweightofoneormorerefractorymetals.In
anotherdisclosednonlimitingembodiment,thesacrificialcore140includesaceramiccore.Inanotherdisclosednonlimiting
embodiment,thesacrificialcore140maybeahybridcore,thatis,hybridofaceramicandarefractorymetal(alloy).The
powdercanhaveaparticlesizeofbetweenabout10micronsand74microns,preferablybetweenabout15micronsand
about30microns.ExamplesofsuitablelasersinteringmachinesareavailablefromEOSNorthAmerica,Inc.ofNovi,
Michigan,USA.

[0052]Althoughthemethodsofmanufacturingthesacrificialcore140havebeendescribedhereinusingDMLS,thoseskilled
intheartofmanufacturingwillrecognizethatanyothersuitablerapidmanufacturingmethodsusinglayerbylayer
constructionoradditivefabricationcanalsobeused.Thesealternativerapidmanufacturingmethodsinclude,butnotlimited
to,SelectiveLaserSintering(SLS),3Dprinting,suchasbyinkjetsandlaserjets,Sterolithography(SLS),DirectSelective
LaserSintering(DSLS),ElectronBeamSintering(EBS),ElectronBeamMelting(EBM),LaserEngineeredNetShaping
(LENS),LaserNetShapeManufacturing(LNSM)andDirectMetalDeposition(DMD).

[0053]Next,thesacrificialcore140isutilizedtomanufacturethefuelcomponentbody142(step204).Example
manufactureprocessesinclude,forexample,diecasting,suchashorizontal,inclinedorverticaldiecastingsystems.That
is,thesacrificialcore140isutilizedtoformtheinternalgeometry136ofthefuelcomponentbody142whichisitselfformed
byoneormoreothermanufacturingprocessessuchasdiecasting.Anotherexamplemanufactureprocessesincludes
investmentcastinginwhichthesacrificialcore140is,forexample,designedtomeltoutofthepatternorremainpartofthe
patternandisremovedaftertheworkpieceiscast.[0054]Followingthediecasting,thefuelcomponentbody142isde
coredtoremovethesacrificialcore140(step206)orpartiallyremovethesacrificialcore140.Exampledecoringtechniques
includedestructivelyremovingthecorebychemicalleaching(e.g.,alkalineand/oracidleaching).Thisstepmaybe
accomplishedindifferentwaysdependinguponthematerialfromwhichthesacrificialcore140ismanufactured.Oncethe
sacrificialcore140isremoved,thefuelcomponentbody142isleftwiththeinternalgeometry136which,inatleastsome
locationsmaybecompletelyselfcontained.

[0055]Thefuelcomponentbody142maythenbesubjectedtofinishingoperations(step208),toincludebutnotbelimited
to,machining,threading,surfacetreating,coatingoranyotherdesirablefinishingoperation.Further,otherseparately
manufacturedcomponentssuchasanozzleinsertandswirlermaybeassembledtothefuelcomponentbody142toform
thefinishedfuelnozzle86via,forexampleabrazeoperationand/orremovableassemblytechniquesuchasthougha
threadedinterface.Itshouldbeappreciatedthatthefuelnozzle86couldincludemoreorlesssections,partsand/or
componentsthereofaswellasotherfuelcomponents,toincludebutnotbelimitedtotheswirler90

[0056]Anewsacrificialcore140isusedtomanufactureeachfuelcomponentbody142andformsnopartofthefinished
fuelnozzle86.Thesacrificialcore140providesaninternalgeometry136heretoforeunavailableexceptwithmultiple
assembledcomponents.

[0057]Itshouldbeunderstoodthatrelativepositionaltermssuchas"forward,""aft,""upper,""lower,""above,""below,"and
thelikearewithreferencetothenormaloperationalattitudeofthevehicleandshouldnotbeconsideredotherwiselimiting.
TrythenewGooglePatents,withmachineclassifiedGoogleScholarresults,andJapaneseandSouthKoreanpatents.

https://www.google.com/patents/WO2015050987A1?cl=en 5/6
6/22/2017 PatentWO2015050987A1AdditivemanufacturedfuelnozzlecoreforagasturbineengineGooglePatents
[0058]Itshouldbeunderstoodthatlikereferencenumeralsidentifycorrespondingorsimilarelementsthroughouttheseveral
drawings.Itshouldalsobeunderstoodthatalthoughaparticularcomponentarrangementisdisclosedintheillustrated
embodiment,otherarrangementswillbenefitherefrom.

[0059]Althoughparticularstepsequencesareshown,described,andclaimed,itshouldbeunderstoodthatstepsmaybe
performedinanyorder,separatedorcombinedunlessotherwiseindicatedandwillstillbenefitfromthepresentdisclosure.

[0060]Theforegoingdescriptionisexemplaryratherthandefinedbythefeatureswithin.Variousnonlimitingembodiments
aredisclosedherein,however,oneofordinaryskillintheartwouldrecognizethatvariousmodificationsandvariationsin
lightoftheaboveteachingswillfallwithinthescopeoftheappendedclaims.Itisthereforetobeunderstoodthatwithinthe
scopeoftheappendedclaims,thedisclosuremaybepracticedotherthanasspecificallydescribed.Forthatreasonthe
appendedclaimsshouldbestudiedtodeterminetruescopeandcontent.

PATENTCITATIONS
CitedPatent Filingdate Publicationdate Applicant Title
US5988531* Nov25,1997 Nov23,1999 SolarTurbines Methodofmakingafuelinjector
GeneralElectric
US20050006047* Jul10,2003 Jan13,2005 Investmentcastingmethodandcoresanddiesusedtherein
Company
Pratt&Whitney
US20060130328* Dec21,2004 Jun22,2006 Gasturbinefuelnozzlemanufacturing
CanadaCorp.
GeneralElectric Componentscapableoftransportingliquidsmanufacturedusing
US20090014561* Jul15,2007 Jan15,2009
Company injectionmolding
Methodsforfabricatinggasturbinecomponentsusinganintegrated
US20100025001* Jun25,2007 Feb4,2010 ChingPangLee
disposablecoreandshelldie
*Citedbyexaminer

NONPATENTCITATIONS
Reference
1 * SeealsoreferencesofEP3052784A4
*Citedbyexaminer

REFERENCEDBY
CitingPatent Filingdate Publicationdate Applicant Title
UnitedTechnologies Additivelymanufacturedcoreforuseincastinganintegralcoolingcircuit
EP3162459A1* Oct25,2016 May3,2017
Corporation ofagasturbineenginecomponent
GeneralElectric Methodandassemblyforformingcomponentshavinginternalpassages
US9579714 Dec17,2015 Feb28,2017
Company usingalatticestructure
*Citedbyexaminer

CLASSIFICATIONS

InternationalClassification B22D17/20,F23R3/28,F02C7/22,F23D11/38,B22C9/10
CooperativeClassification B22C9/103,B22C9/10,B22C9/24,F23R3/286,F05D2230/30,F05D2230/211,F02C7/2365,F23R3/28,F23D11/38,B22D17/20

LEGALEVENTS
Date Code Event Description
Refdocumentnumber:14851160
May20,2015 121 Ep:theepohasbeeninformedbywipothatepwasdesignatedinthisapplication Countryofrefdocument:EP
Kindcodeofrefdocument:A1

Apr4,2016 NENP Nonentryintothenationalphasein: Refcountrycode:DE

Refdocumentnumber:2014851160
May4,2016 REEP
Countryofrefdocument:EP

GoogleHomeSitemapUSPTOBulkDownloadsPrivacyPolicyTermsofServiceAboutGooglePatentsSendFeedback
DataprovidedbyIFICLAIMSPatentServices

TrythenewGooglePatents,withmachineclassifiedGoogleScholarresults,andJapaneseandSouthKoreanpatents.

https://www.google.com/patents/WO2015050987A1?cl=en 6/6