Abstract: A method for providing an anti-coking coating system on a surface at elevated temperatures when contacted by a hydrocarbon fluid, for example, a surface of an interior fuel passage within a fuel nozzle of a type utilized in gas turbine engines, is disclosed. The surface of the passage is rough as a result of the passage being part of a component manufactured by an additive manufacturing (AM) process. In addition, the passage may have a complex geometry of a type that can be fabricated with AM processes, for example, geometries comprising combinations of sharp bends and narrow cross-sections. The coating system comprises at least one ceramic barrier layer and an outermost metallic layer, each of which is formed using a conformal vapor deposition process.

Abstract: A direct metal laser melting (DMLM) system includes a laser device configured to generate a melt pool in a powder bed based on a build parameter. In addition, the DMLM system includes a confocal optical system directed at the melt pool and configured to receive an optical signal emitted by the melt pool. The DMLM system further includes an optical sensor operatively coupled to the confocal optical system that is configured to receive the optical signal and to generate an electrical signal in response to the optical signal. A computing device is configured to receive the electrical signal from the optical sensor and to generate a control signal in response. The control signal is configured to modify the build parameter of the direct metal laser melting system in real-time to adjust at least one of a melt pool size and a melt pool temperature to achieve a desired physical property of the component.

Abstract: A method for providing an anti-coking coating system on a surface at elevated temperatures when contacted by a hydrocarbon fluid, for example, a surface of an interior fuel passage within a fuel nozzle of a type utilized in gas turbine engines, is disclosed. The surface of the passage is rough as a result of the passage being part of a component manufactured by an additive manufacturing (AM) process. In addition, the passage may have a complex geometry of a type that can be fabricated with AM processes, for example, geometries comprising combinations of sharp bends and narrow cross-sections. The coating system comprises at least one ceramic barrier layer and an outermost metallic layer, each of which is formed using a conformal vapor deposition process.

Abstract: A direct metal laser melting (DMLM) system includes a laser device configured to generate a melt pool in a powder bed based on a build parameter. In addition, the DMLM system includes a confocal optical system directed at the melt pool and configured to receive an optical signal emitted by the melt pool. The DMLM system further includes an optical sensor operatively coupled to the confocal optical system that is configured to receive the optical signal and to generate an electrical signal in response to the optical signal. A computing device is configured to receive the electrical signal from the optical sensor and to generate a control signal in response. The control signal is configured to modify the build parameter of the direct metal laser melting system in real-time to adjust at least one of a melt pool size and a melt pool temperature to achieve a desired physical property of the component.

Abstract: A fuel distributor is disclosed comprising a body having a unitary construction, a fuel conduit located within the body, a fuel flow path located within the body that is oriented in a circumferential direction around an axis and in flow communication with the fuel conduit, and at least one orifice located in the body in flow communication with the fuel flow path such that a fuel entering the fuel conduit exits through the orifice.

Abstract: A fuel nozzle apparatus includes: a fuel distributor including an annular distributor ring, an aft interior mounting surface; and a pilot supply tube; a venturi defining a splitter with a first bore, and axially spaced-apart forward and aft exterior mounting surfaces; and a swirler including second bore and a forward interior mounting surface. The pilot supply tube is received in the second bore, outer ends of the inner vanes are received in the first bore; and the forward and aft exterior mounting surfaces of the venturi are received in the forward and aft interior mounting surfaces, respectively.

Abstract: A fuel nozzle for a gas turbine engine is disclosed, the fuel nozzle comprising at least one unitary component made using a rapid manufacturing process. In one aspect, the rapid manufacturing process is a laser sintering process. Unitary components disclosed include a conduit, swirler, distributor, venturi and a centerbody.

Abstract: A method and system for enhancing the heat transfer of turbine engine components is disclosed that includes applying a metallic coating having a high thermal conductivity to the cold side of a turbine component to enhance heat transfer away from the component. The metallic coating may be roughened to improve heat transfer. The metal coating may be a Ni—Al bond coating having an aluminum content greater than about 50 weight percent.

Abstract: A unitary distributor is disclosed, comprising at least one main flow passage located within a distributor ring body, the main flow passage having an arcuate portion oriented in a circumferential direction around a distributor axis. Exemplary embodiments of a unitary distributor having an annular ring located at the axially forward end of the distributor ring body are disclosed. A fuel distributor is disclosed, comprising a fuel conduit and a distributor wherein the fuel distributor has a unitary construction.

Abstract: A method for fabricating a unitary conduit is disclosed the method comprising the steps of determining three-dimensional information of the unitary conduit having at least one flow passage, converting the three-dimensional information into a plurality of slices that each define a cross-sectional layer of the unitary conduit, and successively forming each layer of the unitary conduit by fusing a metallic powder using laser energy. A unitary conduit is disclosed, comprising a body and a flow passage, wherein the flow passage and the body have a unitary construction, and made by using a rapid manufacturing process.

Abstract: A unitary swirler is disclosed, comprising a body having a swirler axis, and a plurality of vanes arranged in a circumferential direction around the swirler axis, wherein the swirler has a unitary construction. In one embodiment, the unitary swirler has a rim located coaxially with the swirler axis, and a wall extending between a portion of the rim and a portion of the hub. In another embodiment, the unitary swirler has an adaptor having a passage that is configured to direct a flow of air towards at least some of the plurality of vanes.

Abstract: A mixer having a unitary construction is disclosed comprising an annular housing having an axis and at least a first swirler having a plurality of vanes arranged circumferentially around the axis such that circumferentially adjacent vanes form at least one flow passage that is oriented at least partially in an axial direction with respect to the axis. In another exemplary embodiment, a mixer having a unitary construction is disclosed comprising a swirler having a plurality of radial vanes arranged circumferentially around the axis and oriented at least partially in a radial direction.

Abstract: A unitary conduit for transporting a fluid is described, the conduit comprising a body and a flow passage located within the body, the flow passage having an inlet end and an exit end, wherein the flow passage and the body have a unitary construction. In another embodiment, a unitary conduit has a flow passage wherein the cross sectional shape of the flow passage changes from a first cross sectional shape to a second cross sectional shape. In another embodiment, the exterior contour of the body generally conforms to the interior contour of the flow passage. In another embodiment, the flow passage branches to a plurality of sub-passages.

Abstract: A method for assembling a fuel nozzle for a turbine engine is provided. The method includes coupling a one-piece housing to a one-piece venturi wherein the housing defines an annular fuel nozzle tip and the venturi defines a fuel chamber within the fuel nozzle tip. The method further includes coupling a one-piece swirler to the venturi such that the swirler extends radially inward from the venturi.

Abstract: A method and system for enhancing the heat transfer of turbine engine components is disclosed that includes applying a metallic coating having a high thermal conductivity to the cold side of a turbine component to enhance heat transfer away from the component. The metallic coating may be roughened to improve heat transfer. The metal coating may be a Ni—Al bond coating having an aluminum content greater than about 50 weight percent.

Abstract: A method for fabricating a unitary conduit is disclosed the method comprising the steps of determining three-dimensional information of the unitary conduit having at least one flow passage, converting the three-dimensional information into a plurality of slices that each define a cross-sectional layer of the unitary conduit, and successively forming each layer of the unitary conduit by fusing a metallic powder using laser energy. A unitary conduit is disclosed, comprising a body and a flow passage, wherein the flow passage and the body have a unitary construction, and made by using a rapid manufacturing process.

Abstract: A unitary swirler is disclosed, comprising a body having a swirler axis, and a plurality of vanes arranged in a circumferential direction around the swirler axis, wherein the swirler has a unitary construction. In one embodiment, the unitary swirler has a rim located coaxially with the swirler axis, and a wall extending between a portion of the rim and a portion of the hub. In another embodiment, the unitary swirler has an adaptor having a passage that is configured to direct a flow of air towards at least some of the plurality of vanes.

Abstract: A method for fabricating a unitary venturi is disclosed, the method comprising the steps of determining three-dimensional information of the unitary venturi having an annular venturi wall and a swirler having a plurality of vanes arranged circumferentially around a swirler axis, converting the three-dimensional information into a plurality of slices that each define a cross-sectional layer of the unitary venturi, and successively forming each layer of the unitary venturi by fusing a metallic powder using laser energy. Exemplary embodiments are disclosed, showing a unitary venturi comprising an annular venturi wall having a swirler axis and a heat shield located at an end wherein unitary venturi is made by using a rapid manufacturing process. In one aspect of the invention, the rapid manufacturing process is a laser sintering process.

Abstract: A venturi is disclosed, the venturi comprising a mixing cavity surrounded circumferentially by an annular venturi wall, and a swirler having a plurality of vanes arranged circumferentially around a swirler axis, wherein the swirler and the annular venturi wall have a unitary construction. In another exemplary embodiment the venturi comprises an annular venturi wall, a swirler located at an axially forward portion of the venturi, the swirler having a plurality of vanes arranged circumferentially around a swirler axis, and a heat shield located axially aft from the swirler, wherein the annular venturi wall, the swirler and the heat shield have a unitary construction.

Abstract: A method for fabricating a unitary distributor is disclosed, the method comprising the steps of determining three-dimensional information of the unitary distributor having at least one flow passage having an arcuate portion located within a distributor ring body having an axis, converting the three-dimensional information into a plurality of slices that each define a cross-sectional layer of the unitary distributor and successively forming each layer of the unitary distributor by fusing a metallic powder using laser energy. A distributor is disclosed comprising a flow passage with an arcuate portion located in a distributor ring body wherein the distributor is made by using a rapid manufacturing process. A unitary fuel distributor comprising a fuel conduit and a distributor is disclosed wherein the unitary fuel distributor is made by using a rapid manufacturing process.