Additively manufactured nozzle tip for fuel injector

Abstract

A fuel injector for a gas turbine engine is disclosed that includes a nozzle tip assembly having a nozzle body substantially monolithically formed by additive manufacturing and having at least one fuel circuit defined therein and at least one air circuit defined therein.

What is claimed is: 
     
         1 . A fuel injector for a gas turbine engine comprising:
 a nozzle tip assembly including a nozzle body substantially monolithically formed by additive manufacturing and having at least one fuel circuit defined therein and at least one air circuit defined therein.   
     
     
         2 . A fuel injector as recited in  claim 1 , wherein the nozzle body has an outer fuel circuit for accommodating transfer of a gaseous fuel and an inner fuel circuit for accommodating transfer of a liquid fuel. 
     
     
         3 . A fuel injector as recited in  claim 2 , wherein the nozzle body has an outer air circuit formed between the outer fuel circuit and the inner fuel circuit. 
     
     
         4 . A fuel injector as recited in  claim 3 , wherein gaseous fuel transfer ports are defined within the nozzle body that extend between the outer fuel circuit and the outer air circuit. 
     
     
         5 . A fuel injector as recited in  claim 3 , wherein liquid fuel transfer ports are defined within the nozzle body that extend between the inner fuel circuit and the outer air circuit. 
     
     
         6 . A fuel injector as recited in  claim 3 , wherein a plurality of axial turning vanes are formed within the outer air circuit. 
     
     
         7 . A fuel injector as recited in  claim 1 , wherein the nozzle tip assembly depends from an end of a feed arm having at least one fuel passage therein to communicate with the at least one fuel circuit. 
     
     
         8 . A fuel injector as recited in  claim 7 , wherein the nozzle tip assembly depends from an end of a feed arm having a first fuel passage to communicate with the outer fuel circuit of the nozzle body and a second fuel passage to communicate with the inner fuel circuit of the nozzle body. 
     
     
         9 . A fuel injector as recited in  claim 1 , wherein the nozzle body is formed by direct metal laser sintering. 
     
     
         10 . A fuel injector as recited in  claim 3 , wherein a pressure atomizer is disposed within an inner air circuit of the nozzle body. 
     
     
         11 . A fuel injector for a gas turbine engine comprising:
 a) a feed arm having a first and second fuel passages; and   b) a nozzle tip assembly depending from an end of the feed arm, wherein the nozzle tip assembly includes a nozzle body that is substantially monolithically formed by additive manufacturing and has a first fuel circuit formed therein for accommodating transfer of a gaseous fuel delivered by the first fuel passage of the feed arm and a second fuel circuit formed therein for accommodating transfer of a liquid fuel delivered by the second fuel passage of the feed arm.   
     
     
         12 . A fuel injector as recited in  claim 11 , wherein the nozzle body includes an outer air circuit formed between the first fuel circuit and the second fuel circuit. 
     
     
         13 . A fuel injector as recited in  claim 12 , wherein gaseous fuel transfer ports are defined within the nozzle body that extend between the outer fuel circuit and the outer air circuit. 
     
     
         14 . A fuel injector as recited in  claim 12 , wherein liquid fuel transfer ports are defined within the nozzle body that extend between the inner fuel circuit and the outer air circuit. 
     
     
         15 . A fuel injector as recited in  claim 11 , wherein a plurality of axial turning vanes are formed within the outer air circuit. 
     
     
         16 . A fuel injector as recited in  claim 11 , wherein the nozzle body is formed by direct metal laser sintering. 
     
     
         17 . A fuel injector for a gas turbine engine comprising:
 a) a feed arm having a first and second fuel passages; and   b) a nozzle tip assembly depending from an end of the feed arm, wherein the nozzle tip assembly includes a nozzle body that is substantially monolithically formed by direct metal laser sintering and has a first fuel circuit formed therein communicating with the first fuel passage of the feed arm, a second fuel circuit formed therein communicating with the second fuel passage of the feed arm, and an air circuit formed between the first fuel circuit and the second fuel circuit.   
     
     
         18 . A fuel injector as recited in  claim 17 , wherein fuel transfer ports are defined within the nozzle body that extend between the first fuel circuit and the air circuit. 
     
     
         19 . A fuel injector as recited in  claim 17 , wherein fuel transfer ports are defined within the nozzle body that extend between the second fuel circuit and the air circuit. 
     
     
         20 . A fuel injector as recited in  claim 17 , wherein a plurality of axial turning vanes are formed within the air circuit.