Method of manufacturing a unitary venturi

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.

1 . A method for fabricating a unitary venturi, said 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. 
   
   
       2 . A method in accordance with  claim 1  wherein determining three-dimensional information of the unitary venturi further comprises determining a three-dimensional model of the unitary venturi. 
   
   
       3 . A method in accordance with  claim 1  wherein successively forming each layer of the unitary venturi 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 venturi 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 venturi 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 venturi further comprises determining a three-dimensional model of the unitary venturi having an annular splitter coaxially located around the swirler axis. 
   
   
       7 . A method in accordance with  claim 1  wherein determining three-dimensional information of the unitary venturi further comprises determining a three-dimensional model of the unitary venturi 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 venturi further comprises determining a three-dimensional model of the unitary venturi having a heat shield located axially aft from the swirler. 
   
   
       9 . A method in accordance with  claim 8  wherein the unitary venturi has at least one slot extending between the venturi wall and the heat shield. 
   
   
       10 . A method in accordance with  claim 1  wherein the venturi wall has a groove capable of receiving a brazing material. 
   
   
       11 . 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. 
   
   
       12 . A unitary venturi according to  claim 11  wherein the rapid manufacturing process is a laser sintering process. 
   
   
       13 . A unitary venturi according to  claim 11  wherein the rapid manufacturing process is DMLS. 
   
   
       14 . A unitary venturi according to  claim 11  further comprising a swirler having a plurality of vanes arranged circumferentially around the swirler axis. 
   
   
       15 . A unitary venturi according to  claim 14  wherein at least one vane has a geometry that is different from another vane. 
   
   
       16 . A unitary venturi according to  claim 11  further comprising an annular splitter coaxially located around the swirler axis. 
   
   
       17 . A unitary venturi according to  claim 11  wherein the heat shield is located at an axially aft end of the venturi. 
   
   
       18 . A unitary venturi according to  claim 11  further comprising a plurality of slots extending between the venturi wall and the heat shield, the slots being arranged circumferentially around the swirler axis. 
   
   
       19 . A unitary venturi according to  claim 18  further comprising a plurality of bumps located on the heat shield and arranged circumferentially around the swirler axis. 
   
   
       20 . A unitary venturi according to  claim 11  wherein the venturi wall has a groove capable of receiving a brazing material. 
   
   
       21 . A venturi according to  claim 11 , further comprising a lip located at an axially aft end of the venturi wall.