Method of repairing a fuel nozzle

Abstract

A method of repairing a fuel nozzle is disclosed comprising the steps of forming a pilot assembly; installing into a repair bore; inserting a primary adaptor into a repair bore such that the primary adaptor is in flow communication with a pilot flow passage and the pilot assembly; and coupling the primary adaptor to a distributor and the new pilot assembly.

1 . A method of repairing a fuel nozzle comprising the steps of:
 removing old pilot assembly;   forming a new pilot assembly;   installing the new pilot assembly into a repair bore;   preparing a primary adaptor for assembly;   inserting the primary adaptor into the repair bore such that the primary adaptor is in flow communication with a pilot flow passage in a distributor and the new pilot assembly; and   coupling the primary adaptor to the distributor and the new pilot assembly.   
   
   
       2 . A method of repairing a fuel nozzle according to  claim 1  further comprising the step of coupling a cover plate to a stem such that the portion of the repair bore in the stem is sealed off. 
   
   
       3 . A method of repairing a fuel nozzle according to  claim 1  wherein the step of removing old pilot assembly comprises the step of drilling through a tip assembly of the fuel nozzle. 
   
   
       4 . A method of repairing a fuel nozzle according to  claim 1  wherein the step of forming a new pilot assembly comprises the step of forming a new primary pilot assembly by coupling a fuel swirler to a primary orifice. 
   
   
       5 . A method of repairing a fuel nozzle according to  claim 4  wherein the step of coupling a fuel swirler to the primary orifice is performed by brazing. 
   
   
       6 . A method of repairing a fuel nozzle according to  claim 4  further comprising the step of coupling the new primary pilot assembly to a secondary orifice. 
   
   
       7 . A method of assembling a fuel nozzle according to  claim 6  wherein the step of coupling the new primary pilot assembly to a secondary orifice is performed by a press-fit. 
   
   
       8 . A method of repairing a fuel nozzle according to  claim 6  further comprising the step of preparing the secondary orifice for brazing by inserting a preformed braze wire into a braze-groove in the secondary orifice. 
   
   
       9 . A method of repairing a fuel nozzle according to  claim 1  wherein installing the new pilot assembly into a repair bore comprises the step of locating the new pilot assembly to be substantially coaxial with a nozzle tip assembly axis  11  using a placement fixture. 
   
   
       10 . A method of repairing a fuel nozzle according to  claim 9  wherein the step of locating the new pilot assembly comprises locating the secondary orifice in the nozzle tip assembly using a detent located on the secondary orifice. 
   
   
       11 . A method of repairing a fuel nozzle according to  claim 1  wherein the step of preparing a primary adaptor comprises the step of inserting at least one preformed braze wire into at least one braze-groove located in the primary adaptor. 
   
   
       12 . A method of repairing a fuel nozzle according to  claim 1  wherein the step of inserting the primary adaptor further comprises the step of inserting a portion of the primary adaptor into a portion of the primary pilot assembly. 
   
   
       13 . A method of repairing a fuel nozzle according to  claim 1  wherein the step of coupling the primary adaptor to the distributor is performed by brazing. 
   
   
       14 . A method of repairing a fuel nozzle according to  claim 1  wherein the step of coupling the primary adaptor to the distributor comprises brazing using a braze material in a preformed braze-groove located in the primary adaptor. 
   
   
       15 . A method of repairing a fuel nozzle according to  claim 1  wherein the step of coupling the primary adaptor to new pilot assembly is performed by brazing. 
   
   
       16 . A method of repairing a fuel nozzle according to  claim 1  wherein the step of coupling the primary adaptor to new pilot assembly comprises brazing using a braze material in a preformed braze-groove located in the primary adaptor. 
   
   
       17 . A method of repairing a fuel nozzle according to  claim 2  wherein the step of coupling a cover plate to a stem is performed by welding. 
   
   
       18 . A method of repairing a fuel nozzle comprising the steps of:
 coupling a primary adaptor having an interior flow passage such that the primary adaptor is in flow communication with a flow passage in a distributor wherein the primary adaptor is made using a rapid manufacturing process.   
   
   
       19 . A method of repairing a fuel nozzle according to  claim 18  wherein the rapid manufacturing process is a laser sintering process. 
   
   
       20 . A method of repairing a fuel nozzle according to  claim 18  wherein the step of coupling the primary adaptor is performed by brazing.