当前申请(专利权)人地址：
Incorporated in USA - New York, 1 River Road, Schenectady, New York 12345, United States of America
摘要：
A method for fabricating a unitary component for a combustor is disclosed, said method comprising the steps of determining three-dimensional information of the unitary component 60, converting the three-dimension-al information into a plurality of slices that each define a cross-sectional layer of the unitary component 60, and successively forming each layer of the unitary component 60 by fusing a metallic powder using laser energy. A combustor component 60, 50 is disclosed, comprising a body 61, 51 having a unitary construction wherein the body 61, 51 is made by using a rapid manufacturing process.
权利要求：
WHAT IS CLAIMED IS:
1. A method for fabricating a unitary component for a fuel nozzle 5, said method comprising: determining three-dimensional information of the unitary component 60; converting the three-dimensional information into a plurality of slices that each define a cross-sectional layer of the unitary component 60; and successively forming each layer of the unitary component 60 by fusing a metallic powder using laser energy.
2. A method in accordance with claim 1 wherein determining three-dimensional information of the unitary component further comprises determining a three- dimensional model of the unitary component 60.
3. A method in accordance with claim 1 wherein successively forming each layer of the unitary component by fusing a metallic powder using laser energy further comprises fusing a powder comprising at least one of cobalt chromium, HS 188 and INCO 625.
4. A method in accordance with claim 1 wherein successively forming each layer of the unitary component 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 component 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 component further comprises determining a three- dimensional model of the unitary component 60 having an internal conduit 65.
7. A method in accordance with claim 1 wherein determining three-dimensional information of the unitary component further comprises determining a three- dimensional model of the unitary component 60 having a plurality of holes 82.
8. A method in accordance with claim 1 wherein determining three-dimensional information of the unitary component further comprises determining a three- dimensional model of the unitary component 50 having a plurality of vanes 52, 54.
9. A method in accordance with claim 1 wherein the unitary component is a fuel distributor 60.
10. A method in accordance with claim 1 wherein the unitary component is an air swirler 50.
11. A combustor component 60, 50 comprising a body 61, 51 having a unitary construction wherein the body 61, 51 is made by using a rapid manufacturing process.
12. A combustor component 60, 50 according to claim 11 wherein the rapid manufacturing process is a laser sintering process.
13. A combustor component 60, 50 according to claim 11 wherein the rapid manufacturing process is DMLS.
14. A combustor component 60 according to claim 11 wherein the body 61 has an internal conduit 65.
15. A combustor component 60 according to claim 11 wherein the body 61 has a row of holes 82.
16. A combustor component 60 according to claim 11 wherein the component is a fuel distributor 60.
17. A combustor component 50 according to claim 11 wherein the component is an air swirler 50.
18. A combustor component 50 according to claim 11 wherein the component is an air swirler 50 having at least one row of vanes 52.
19. A combustor component 60 according to claim 11 wherein the component is a fuel nozzle component 60.
20. A combustor component 60 according to claim 19 wherein the fuel nozzle component is a fuel distributor 60.
21. A combustor component 60 comprising:
a body 61 having a unitary construction;
a fuel conduit 12 located within the body 61 that is oriented in a substantially axial direction;
a fuel flow path 62 located within the body 61 that is oriented in a circumferential direction around an axis 11 and in flow communication with the fuel conduit 12; and
at least one orifice 68 located in the body 61 in flow communication with the fuel flow path 62 such that a fuel entering the fuel conduit 12 exits through the orifice 68.
22. A combustor component 60 according to claim 21 wherein the fuel entering the fuel conduit 12 exits through the orifice 68 into a recess 68 in the body 61.
23. A combustor component 60 according to claim 22 further comprising:
a centerbody 70 having a unitary construction with the body 61, the centerbody 70 having an annular wall 74 surrounding the body 61 and having a circumferential row of openings 71 corresponding to a plurality of orifices 68 arranged circumferentially around the axis 11.
24. A combustor component 60 according to claim 23 further comprising:
at least one circumferential row of openings 80 located on the wall 74 capable of flowing cooling air over a portion of the wall 74.
25. A combustor component 60 according to claim 24 wherein the openings 80 are diffuser holes.
26. A combustor component 60 according to claim 21 further comprising: an annular heat shield 72 located at one end of the body 61 such that it is capable of shielding the body 61 from a flame located axially aft from it.
27. A combustor component 60 according to claim 26 wherein the body 61 has a circumferential row of axial openings 82 capable of flowing cooling air towards the heat shield 72.
28. A fuel distributor 60 comprising:
a body 61 having a unitary construction;
a plurality of fuel conduits 12, 14 located within the body 61 oriented in a substantially axial direction and having a substantially constant flow area;
a plurality of fuel flow paths 62, 64 located within the body 61 oriented in a circumferential direction around an axis 11 in flow communication with at least one of the fuel conduits 12, 14 and having a flow area that varies in the circumferential direction; and
a plurality of orifices 68 located in the body 61 in flow communication with at least one of the plurality of fuel flow paths 62, 64 arranged circumferentially around the axis 11 such that a fuel entering the fuel conduits 12, 14 exits through the orifices 68.
29. A fuel distributor 60 according to claim 28 wherein the fuel entering the fuel conduit 12 exits through the orifices 68 into a plurality of recesses 68 in the body 61.
30. A fuel distributor 60 according to claim 28 further comprising:
a centerbody 70 having unitary construction with the body 61, the centerbody 70 having an annular wall 74 surrounding the body 61 and having a circumferential row of openings 71 corresponding to the plurality of orifices 68.
31. A fuel distributor 60 according to claim 30 further comprising:
at least one circumferential row of openings 80 located on the wall 74 capable of flowing cooling air over a portion of the wall 74.
32. A fuel distributor 60 according to claim 31 wherein the openings 80 are diffuser holes.
33. A fuel distributor 60 according to claim 28 further comprising:
an annular heat shield 72 located at one end of the body 61 such that it is capable of shielding the body 61 from a flame located axially aft from it.
34. A fuel distributor 60 according to claim 33 wherein the body 61 has a circumferential row of axial openings 82 capable of flowing cooling air towards the heat shield 72.
35. A fuel nozzle 5 comprising:
an annular fuel distributor 60 having a unitary construction and having at least one fuel conduit 12 oriented in a substantially axial direction within a body 61 and having at least one fuel flow path 62 within the body 61 in flow communication with the fuel conduit 12 and oriented in a circumferential direction around an axis 11;
an annular air swirler 50 located radially inside the unitary fuel distributor 60 capable of swirling an air stream entering the air swirler 50; and
a fuel injector 22 located radially inside the annular air swirler 50 capable of injecting a stream of fuel into a mixing chamber 76 such that the fuel and air are mixed within the mixing chamber 76.
36. A fuel nozzle 5 according to claim 35 further comprising:
a centerbody 70 having unitary construction with the body 61, the centerbody 70 having an annular wall 74 surrounding the body 61 and having a circumferential row of openings 71 corresponding to a plurality of orifices 68 located within the body 61 arranged circumferentially around the axis 11.
37. A fuel nozzle 5 according to claim 36 further comprising:
at least one circumferential row of openings 80 located on the wall 74 capable of flowing cooling air over a portion of the wall 74.
38. A fuel distributor 60 according to claim 37 wherein the openings 80 are diffuser holes.
39. A fuel nozzle 5 according to claim 35 further comprising:
an annular heat shield 72 located at one end of the body 61 such that it is capable of shielding the body 61 from a flame located axially aft from it.
40. A fuel nozzle 5 according to claim 39 further comprising:
at least one row of axial flow holes 82 located on the body 61 capable of flowing cooling air towards the heat shield 72.
41. An air s wirier 50 comprising:
an annular body 51 ;
a row of outer vanes 54 located on the annular body 51 arranged circumferentially around an axis 11 ;
a row of inner vanes 52 located on the annular body 51 arranged circumferentially around the axis 11 and located radially inner to the row of outer vanes 54; and
an annular splitter 53 located on the body 51, wherein the annular body 51, the row of outer vanes 54, the row of inner vanes 52 and the annular splitter 53 have a unitary construction.