Patent Description:
This invention was made with Government support under Contract No. <CIT> awarded by the United States Department of Energy. The Government has certain rights in this invention.

Turbomachines are utilized in a variety of industries and applications for energy transfer purposes. For example, a gas turbine engine generally includes a compressor section, a combustion section, a turbine section, and an exhaust section. The compressor section progressively increases the pressure of a working fluid entering the gas turbine engine and supplies this compressed working fluid to the combustion section. The compressed working fluid and a fuel (e.g., natural gas) mix within the combustion section and burn in a combustion chamber to generate high pressure and high temperature combustion gases. The combustion gases flow from the combustion section into the turbine section where they expand to produce work. For example, expansion of the combustion gases in the turbine section may rotate a rotor shaft connected, e.g., to a generator to produce electricity. The combustion gases then exit the gas turbine via the exhaust section.

In many turbomachine combustors, combustion gases are routed towards an inlet of a turbine section of the gas turbine through a hot gas path that is at least partially defined by a combustion liner that extends downstream from a fuel nozzle and terminates at the inlet to the turbine section. Accordingly, high combustion gas temperatures within the turbine section generally corresponds to greater thermal and kinetic energy transfer between the combustion gases and the turbine, thereby enhancing overall power output of the turbomachine. However, the high combustion gas temperatures may lead to erosion, creep, and/or low cycle fatigue to the various components of the combustor, thereby limiting its overall durability.

Thus, it is necessary to cool the components of the combustor, which is typically achieved by routing a cooling medium, such as the compressed working fluid from the compressor section, to various portions of the combustion liner. However, utilizing a large portion of compressed working fluid from the compressor section may negatively impact the overall operating efficiency of the turbomachine because it decreases the amount of working fluid that is utilized in the turbine section. Accordingly, an improved system for cooling a turbomachine combustor is desired in the art. In particular, a system that efficiently utilizes compressed working fluid from the compressor would be useful. <CIT> discloses a jet pipe liner for a gas turbine engine, consisting of longitudinally extending inner skin segments suspended by longitudinally extending A-frame members attached to the inside of the jet pipe. Radially outer skin panels are provided spaced apart from the inner skin segments. <CIT> relates to a cooling structure for a gas turbine combustor, in which walls of a combustor liner, transition duct, etc. are cooled by impinging jets of a cooling medium.

<CIT> proposes a combustor comprising an impingement panel configured to provide impingement cooling to an exterior surface of an outer or an inner liner segment of the combustor.

<CIT> concerns an impingement panel and its method of manufacturing.

Aspects and advantages of the assemblies and methods in accordance with the present disclosure will be set forth in part in the following description, or may be obvious from the description, or may be learned through practice of the technology.

In accordance with the invention, an integrated combustor nozzle is provided as defined in the accompanying claims.

In accordance with another embodiment, a method for fabricating an integrated combustor nozzle is provided as defined in the accompanying claims.

These and other features, aspects and advantages of the present assemblies and methods will become better understood with reference to the following description and appended claims.

A full and enabling disclosure of the present assemblies, including the best mode of making and using the present systems and methods, directed to one of ordinary skill in the art, is set forth in the specification, which makes reference to the appended figures, in which:.

Reference now will be made in detail to embodiments of the present assemblies, one or more examples of which are illustrated in the drawings. Each example is provided by way of explanation, rather than limitation of, the technology. In fact, it will be apparent to those skilled in the art that modifications and variations can be made in the present technology without departing from the scope of the appended claims. Thus, it is intended that the present disclosure covers such modifications and variations as come within the scope of the appended claims.

As used herein, the terms "first," "second," and "third" may be used interchangeably to distinguish one component from another and are not intended to signify location or importance of the individual components.

As used herein, the terms "upstream" (or "forward") and "downstream" (or "aft") refer to the relative direction with respect to fluid flow in a fluid pathway. The term "radially" refers to the relative direction that is substantially perpendicular to an axial centerline of a particular component, the term "axially" refers to the relative direction that is substantially parallel and/or coaxially aligned to an axial centerline of a particular component and the term "circumferentially" refers to the relative direction that extends around the axial centerline of a particular component. Terms of approximation, such as "generally," "substantially," "approximately," or "about" include values within ten percent greater or less than the stated value. When used in the context of an angle or direction, such terms include within ten degrees greater or less than the stated angle or direction. For example, "generally vertical" includes directions within ten degrees of vertical in any direction, e.g., clockwise or counterclockwise.

Referring now to the drawings, <FIG> illustrates a schematic diagram of one embodiment of a turbomachine, which in the illustrated embodiment is a gas turbine <NUM>. Although an industrial or land-based gas turbine is shown and described herein, the present disclosure is not limited to a land based and/or industrial gas turbine unless otherwise specified in the claims. For example, the invention as described herein may be used in any type of turbomachine including but not limited to a steam turbine, an aircraft gas turbine, or a marine gas turbine.

As shown, the gas turbine <NUM> generally includes an inlet section <NUM>, a compressor <NUM> disposed downstream of the inlet section <NUM>, a combustion section <NUM> disposed downstream of the compressor <NUM>, a turbine <NUM> disposed downstream of the combustion section <NUM>, and an exhaust section <NUM> disposed downstream of the turbine <NUM>. Additionally, the gas turbine <NUM> may include one or more shafts <NUM> that couple the compressor <NUM> to the turbine <NUM>.

During operation, air <NUM> flows through the inlet section <NUM> and into the compressor <NUM> where the air <NUM> is progressively compressed, thus providing compressed air <NUM> to the combustion section <NUM>. At least a portion of the compressed air <NUM> is mixed with a fuel <NUM> within the combustion section <NUM> and burned to produce combustion gases <NUM>. The combustion gases <NUM> flow from the combustion section <NUM> into the turbine <NUM>, wherein energy (kinetic and/or thermal) is transferred from the combustion gases <NUM> to rotor blades (not shown), thus causing shaft <NUM> to rotate. The mechanical rotational energy may then be used for various purposes, such as to power the compressor <NUM> and/or to generate electricity. The combustion gases <NUM> exiting the turbine <NUM> may then be exhausted from the gas turbine <NUM> via the exhaust section <NUM>.

<FIG> provides an upstream view of the combustion section <NUM>, according to various embodiments of the present disclosure. As shown in <FIG>, the combustion section <NUM> may be at least partially surrounded by an outer or compressor discharge casing <NUM>. The compressor discharge casing <NUM> may at least partially define a high pressure plenum <NUM> that at least partially surrounds various components of the combustor <NUM>. The high pressure plenum <NUM> may be in fluid communication with the compressor <NUM> (<FIG>) so as to receive the compressed air <NUM> therefrom. In various embodiments, as shown in <FIG>, the combustion section <NUM> includes a segmented annular combustion system <NUM> that includes a number of integrated combustor nozzles <NUM> arranged circumferentially around an axial centerline <NUM> of the gas turbine <NUM>, which may be coincident with the gas turbine shaft <NUM>.

<FIG> provides a perspective view of an integrated combustor nozzle <NUM>, as viewed from a first side. Similarly, <FIG> provides a perspective view of an integrated combustor nozzle <NUM>, as viewed from a second side, in accordance with embodiments of the present disclosure. As shown collectively in <FIG>, <FIG>, the segmented annular combustion system <NUM> includes a plurality of integrated combustor nozzles <NUM>. As described further herein, each combustor nozzle <NUM> includes a first side wall <NUM> and a second side wall <NUM>. In particular embodiments, the first side wall is a pressure side wall, while the second side wall is a suction side wall, based on the integration of the side walls with corresponding pressure and suction sides of a downstream turbine nozzle <NUM>. It should be understood that any references made herein to pressure side walls and suction side walls are representative of particular embodiments, such references being made to facilitate discussion, and that such references are not intended to limit the scope of any embodiment, unless specific context dictates otherwise.

As shown collectively in <FIG>, each circumferentially adjacent pair of combustor nozzles <NUM> defines a respective primary combustion zone <NUM> and a respective secondary combustion zone <NUM> therebetween, thereby forming an annular array of primary combustion zones <NUM> and secondary combustion zones <NUM>. The primary combustion zones <NUM> and the secondary combustion zones <NUM> are circumferentially separated, or fluidly isolated, from adjacent primary combustion zones <NUM> and secondary combustion zones <NUM>, respectively, by the combustion liners <NUM>.

As shown collectively in <FIG>, each combustor nozzle <NUM> includes an inner liner segment <NUM>, an outer liner segment <NUM>, and a hollow or semi-hollow combustion liner <NUM> that extends between the inner liner segment <NUM> and the outer liner segment <NUM>. It is contemplated that more than one (e.g., <NUM>, <NUM>, <NUM>, or more) combustion liners <NUM> may be positioned between the inner liner segment <NUM> and the outer liner segment <NUM>, thereby reducing the number of joints between adjacent liner segments that require sealing. For ease of discussion herein, reference will be made to integrated combustor nozzles <NUM> having a single combustion liner <NUM> between respective inner and outer liner segments <NUM>, <NUM>, although a <NUM>:<NUM> ratio of liner segments to combustion liners is not required. As shown in <FIG>, each combustion liner <NUM> includes forward or upstream end portion <NUM>, an aft or downstream end portion <NUM>, a first side wall <NUM>, which is a pressure side wall in the particular example embodiment illustrated in <FIG> and a second side wall <NUM>, which is a suction side wall in the particular example embodiment illustrated in <FIG>.

The segmented annular combustion system <NUM> further includes a fuel injection module <NUM>. In the illustrated example embodiment, the fuel injection module <NUM> includes a plurality of fuel nozzles. The fuel injection module <NUM> is configured for installation in the forward end portion <NUM> of a respective combustion liner <NUM>. For purposes of illustration herein, the fuel injection module <NUM> including the plurality of fuel nozzles may be referred to as a "bundled tube fuel nozzle. " However, the fuel injection module <NUM> may include or comprise any type of fuel nozzle or burner (such as a swirling fuel nozzle or swozzle), and the claims should be not limited to a bundled tube fuel nozzle unless specifically recited as such.

Each fuel injection module <NUM> may extend at least partially circumferentially between two circumferentially adjacent combustion liners <NUM> and/or at least partially radially between a respective inner liner segment <NUM> and outer liner segment <NUM> of the respective combustor nozzle <NUM>. During axially staged fuel injection operation, the fuel injection module <NUM> provides a stream of premixed fuel and air (that is, a first combustible mixture) to the respective primary combustion zone <NUM>.

In at least one embodiment, as shown in <FIG>, the downstream end portion <NUM> of one or more of the combustion liners <NUM> transitions into a generally airfoil-shaped turbine nozzle <NUM>, which directs and accelerates the flow of combustion products toward the turbine blades. Thus, the downstream end portion <NUM> of each combustion liner <NUM> may be considered an airfoil without a leading edge. When the integrated combustor nozzles <NUM> are mounted within the combustion section <NUM>, the turbine nozzle <NUM> may be positioned immediately upstream from a stage of turbine rotor blades of the turbine <NUM>.

As used herein, the term "integrated combustor nozzle" refers to a seamless structure that includes the combustion liner <NUM>, the turbine nozzle <NUM> downstream of the combustion liner, the inner liner segment <NUM> extending from the forward end <NUM> of the combustion liner <NUM> to the aft end <NUM> (embodied by the turbine nozzle <NUM>), and the outer liner segment <NUM> extending from the forward end <NUM> of the combustion liner <NUM> to the aft end <NUM> (embodied by the turbine nozzle <NUM>). In at least one embodiment, the turbine nozzle <NUM> of the integrated combustor nozzle <NUM> functions as a first-stage turbine nozzle and is positioned upstream from a first stage of turbine rotor blades.

As described above, one or more of the integrated combustor nozzles <NUM> is formed as an integral, or unitary, structure or body that includes the inner liner segment <NUM>, the outer liner segment <NUM>, the combustion liner <NUM>, and the turbine nozzle <NUM>. The integrated combustor nozzle <NUM> may be made as an integrated or seamless component, via casting, additive manufacturing (such as 3D printing), or other manufacturing techniques. By forming the combustor nozzle <NUM> as a unitary or integrated component, the need for seals between the various features of the combustor nozzle <NUM> may be reduced or eliminated, part count and costs may be reduced, and assembly steps may be simplified or eliminated. In other embodiments, the combustor nozzle <NUM> may be fabricated, such as by welding, or may be formed from different manufacturing techniques, where components made with one technique are joined to components made by the same or another technique.

In particular embodiments, at least a portion or all of each integrated combustor nozzle <NUM> may be formed from a ceramic matrix composite (CMC) or other composite material. In other embodiments, a portion or all of each integrated combustor nozzle <NUM> and, more specifically, the turbine nozzle <NUM> or its trailing edge, may be made from a material that is highly resistant to oxidation (e.g., coated with a thermal barrier coating) or may be coated with a material that is highly resistant to oxidation.

In another embodiment (not shown), at least one of the combustion liners <NUM> may taper to a trailing edge that is aligned with a longitudinal (axial) axis of the combustion liner <NUM>. That is, the combustion liner <NUM> may not be integrated with a turbine nozzle <NUM>. In these embodiments, it may be desirable to have an uneven count of combustion liners <NUM> and turbine nozzles <NUM>. The tapered combustion liners <NUM> (i.e., those without integrated turbine nozzles <NUM>) may be used in an alternating or some other pattern with combustion liners <NUM> having integrated turbine nozzles <NUM> (i.e., integrated combustor nozzles <NUM>).

At least one of the combustion liners <NUM> may include at least one cross-fire tube <NUM> that extends through respective openings in the pressure side wall <NUM> and the suction side wall <NUM> of the respective combustion liner <NUM>. The cross-fire tube <NUM> permits cross-fire and ignition of circumferentially adjacent primary combustion zones <NUM> between circumferentially adjacent integrated combustor nozzles <NUM>.

In many embodiments, as shown in <FIG>, each combustion liner <NUM> may include a plurality of radially spaced pressure side injection outlets <NUM> defined along the pressure side wall <NUM>, through which the pressure side fuel injectors <NUM> may extend (<FIG>). As shown in <FIG>, each combustion liner <NUM> may include a plurality of radially spaced suction side injection outlets <NUM> defined along the suction side wall <NUM>, through which the suction side fuel injectors <NUM> may extend (<FIG>). Each respective primary combustion zone <NUM> is defined upstream from the corresponding pressure side injection outlets <NUM> and/or suction side injection outlets <NUM> of a pair of circumferentially adjacent integrated combustor nozzles <NUM>. Each secondary combustion zone <NUM> is defined downstream from the corresponding pressure side injection outlets <NUM> and/or suction side injection outlets <NUM> of the pair of circumferentially adjacent integrated combustor nozzles <NUM>. Although the plurality of pressure side injection outlets <NUM> are shown in <FIG> as residing in a common radial or injection plane with respect to an axial centerline of the integrated combustor nozzle <NUM> or at a common axial distance from the downstream end portion <NUM> of the fuel injection panel <NUM>, in particular embodiments, one or more of the pressure side injection outlets <NUM> may be staggered axially with respect to radially adjacent pressure side injection outlets <NUM>, thereby off-setting the axial distances of the pressure side injection outlets <NUM> to the downstream end portion <NUM> for particular pressure side injection outlets <NUM>. Similarly, although <FIG> illustrates the plurality of suction side injection outlets <NUM> in a common radial or injection plane or at a common axial distance from the downstream end portion <NUM> of the fuel injection panel <NUM>, in particular embodiments, one or more of the suction side injection outlets <NUM> may be staggered axially with respect to radially adjacent suction side injection outlets <NUM>, thereby off-setting the axial distances of the pressure side injection outlets <NUM> to the downstream end portion <NUM> for particular suction side injection outlets <NUM>.

During operation of the segmented annular combustion system <NUM>, it may be necessary to cool one or more of the pressure side walls <NUM>, the suction side walls <NUM>, the turbine nozzle <NUM>, the inner liner segments <NUM>, and/or the outer liner segments <NUM> of each integrated combustor nozzle <NUM> in order to enhance mechanical performance of each integrated combustor nozzle <NUM> and of the segmented annular combustion system <NUM> overall. In order to accommodate cooling requirements, each integrated combustor nozzle <NUM> may include various air passages or cavities, and the various air passages or cavities may be in fluid communication with the high pressure plenum <NUM> formed within the compressor discharge casing <NUM> and/or with the premix air plenum <NUM> defined within each combustion liner <NUM>.

<FIG> illustrates a perspective view of an integrated combustor nozzle <NUM>, which is shown having various cooling components exploded away, in accordance with embodiments of the present disclosure. In various embodiments, as shown, an interior portion of each combustion liner <NUM> may be defined between the pressure side wall <NUM> and the suction side wall <NUM> and may be partitioned into various air passages or cavities <NUM>, <NUM> by one or more ribs <NUM>, <NUM>. In particular embodiments, the air cavities <NUM>, <NUM> may receive air from the compressor discharge casing <NUM> or other cooling source. The ribs or partitions <NUM>, <NUM> may extend within the interior portion of the combustion liner <NUM> to at least partially form or separate the plurality of air cavities <NUM>, <NUM>. In particular embodiments, some or all of the ribs <NUM>, <NUM> may provide structural support to the pressure side wall <NUM> and/or the suction side wall <NUM> of the combustion liner <NUM>.

In particular embodiments, as shown in <FIG>, each integrated combustor nozzle <NUM> may include one or more outer impingement panels <NUM> that extends along an exterior surface <NUM> of the outer liner segment <NUM>. The outer impingement panels <NUM> may have a shape corresponding to the shape, or a portion of the shape, of the outer liner segment <NUM>. In many embodiments, the outer impingement panel <NUM> may define a plurality of impingement holes <NUM> defined at various locations along the outer impingement panel <NUM> (<FIG>). In many embodiments, as shown best in <FIG>, the outer impingement panels <NUM> may be disposed both sides of the cavities <NUM>, <NUM>, in order to provide impingement cooling to the entire outer liner segment <NUM>.

Similarly, each integrated combustor nozzle <NUM> may include an inner impingement panel <NUM> that extends along an exterior surface <NUM> of the inner liner segment <NUM>. The inner impingement panel <NUM> may have a shape corresponding to the shape, or a portion of the shape, of the inner liner segment <NUM>. In many embodiments, as shown best in <FIG>, the inner impingement panel <NUM> may be disposed on both sides of the cavities <NUM>, <NUM>, in order to provide impingement cooling to the entire inner liner segment <NUM>.

As shown in <FIG>, one or more of the integrated combustor nozzles <NUM> may further include cooling inserts <NUM> that are positioned proximate the forward end <NUM> of the combustion liner <NUM> and an impingement cooling apparatus <NUM> that is positioned proximate the aft end <NUM> of the combustion liner <NUM>. As shown and described in detail below, the cooling inserts may be positioned within the cavity <NUM>, such that the cooling inserts <NUM> are housed within the interior of the combustion liner <NUM> to provide cooling thereto. Similarly, the impingement cooling apparatus <NUM> may be housed within the cavity <NUM>, such that the impingement cooling apparatus <NUM> is housed within the interior of the combustion liner <NUM> to provide cooling thereto. As described in more detail below, both the cooling inserts <NUM> and the impingement cooling apparatus <NUM> may be formed as a substantially hollow (or semi-hollow) structure, with an opening at one or both ends, in a shape complementary to the air cavity <NUM>. During operation, air from the compressor discharge casing <NUM> may flow through one or both of the cooling inserts <NUM> and/or the impingement cooling apparatus <NUM>, where the air may flow through impingement holes as discrete jets, which impinge on interior surfaces of the combustion liner <NUM> thereby allowing heat to transfer convectively from the interior surfaces of the combustion liner <NUM> to the cooling air. As discussed in detail below, after impinging on the interior surfaces of the combustion liner <NUM>, a portion of the air passed through the cooling insets <NUM> and/or the impingement cooling apparatus <NUM> may be flowed through the combustion liner <NUM> towards the fuel injectors where the air may be mixed with fuel and used for combustion in the secondary combustion zone <NUM>. In this way, the air that is used for cooling the combustion liner <NUM> is also used to produce work in the turbine section <NUM>, thereby increasing the overall efficiency of the gas turbine <NUM>.

In many embodiments, as shown, two cooling inserts <NUM> may be installed within the air cavity <NUM>, such as a first cooling insert <NUM> installed through the inner liner segment <NUM> and a second cooling insert <NUM> installed through the outer liner segment <NUM>. Such an assembly may be useful when the integrated combustor nozzle <NUM> includes a cross-fire tube <NUM> that prevents insertion of a single impingement air insert <NUM> through the radial dimension of the cavity <NUM>. Alternately, two or more impingement air inserts <NUM> may be positioned sequentially in the axial direction A (the axial direction A is indicated, e.g., in <FIG>) within a given cavity, e.g., on either side of the cross-fire tube <NUM>.

<FIG> illustrates a cross-sectional schematic view of an integrated combustor nozzle <NUM>, in accordance with embodiments of the present disclosure. As shown in <FIG>, the integrated combustor nozzle <NUM> may further include a pressure side fuel injector <NUM>. In many embodiments, the integrated combustor nozzle <NUM> may include a plurality of pressure side fuel injectors <NUM> spaced apart from one another along the radial direction R. For example, each of the pressure side fuel injectors <NUM> may extend from an inlet <NUM> positioned within the combustion liner <NUM> proximate the suction side wall <NUM> to the pressure side injection outlet <NUM>. Similarly, in many embodiments, the integrated combustor nozzle <NUM> may include a plurality of suction side fuel injectors <NUM> spaced apart from one another along the radial direction R. For example, each of the suction side fuel injectors <NUM> may extend from an inlet <NUM> positioned within the combustion liner <NUM> proximate the pressure side wall <NUM> to the suction side injection outlet <NUM>. The fuel injectors <NUM>, <NUM> may provide a secondary mixture of fuel and air to the secondary combustion zone <NUM> downstream from the primary combustion zone <NUM>, in order to increase the temperature of the combustion gases before they enter the turbine section <NUM> and are used to produce work.

In various embodiments, as shown in <FIG>, the fuel injectors <NUM>, <NUM> may be positioned axially between the cooling insert(s) <NUM> and the impingement cooling apparatus <NUM>. In particular embodiments, the pressure side fuel injector <NUM> may be positioned axially between the impingement cooling apparatus <NUM> and the suction side fuel injector <NUM>. Likewise, the suction side fuel injector <NUM> may be positioned axially between the cooling insert(s) <NUM> and the pressure side fuel injector <NUM>.

In particular embodiments, the integrated combustor nozzle <NUM> may include a frame <NUM> and ribs <NUM>, <NUM>. The frame <NUM> may extend around and support the fuel injectors <NUM>, <NUM>. Further, the frame <NUM> may at least partially define a path for air to travel before entering the fuel injectors <NUM>, <NUM>. Each of the ribs <NUM>, <NUM> may extend between the pressure side wall <NUM> and the suction side wall <NUM>. As shown in <FIG>, the ribs <NUM>, <NUM> may include one or more openings defined therethrough in order to provide for fluid communication between the fuel injectors <NUM>, <NUM> and the cooling insert <NUM> or the impingement cooling apparatus <NUM>.

As shown, the various arrows illustrate the flow path of air within the combustion liner <NUM>. For example, the integrated combustor nozzle <NUM> may further include pre-impingement air <NUM> and post-impingement air or spent cooling air <NUM>. As shown in <FIG>, the pre-impingement air <NUM> may exit the cooling insert <NUM> via a first plurality of impingement apertures <NUM> (<FIG>) and a second plurality of impingement apertures <NUM> (<FIG>) defined on each of the walls <NUM>, <NUM>, respectively. Similarly, pre-impingement air <NUM> may exit the impingement cooling apparatus <NUM> via a plurality of impingement apertures <NUM> defined on each of the impingement members <NUM> (<FIG>). The impingement apertures <NUM>, <NUM>, <NUM> may be sized and oriented to direct the pre-impingement air <NUM> in discrete jets to impinge upon the interior surface <NUM> of the pressure side wall <NUM> or the interior surface <NUM> of the suction side wall <NUM>. The discrete jets of air impinge (or strike) the interior surface <NUM>,<NUM> and create a thin boundary layer of air over the interior surface <NUM>, <NUM>, which allows for optimal heat transfer between the walls <NUM>, <NUM> and the air. For example, the impingement apertures <NUM>, <NUM>, <NUM> may orient pre-impingement air such that it is perpendicular to the surface upon which it strikes, e.g. the interior surface <NUM>, <NUM> of the walls <NUM>, <NUM>. Once the air has impinged upon the interior surface <NUM>, <NUM>, it may be referred to as "post-impingement air" and/or "spent cooling air" because the air has undergone an energy transfer and therefore has different characteristics. For example, the spent cooling air <NUM> may have a higher temperature and lower pressure than the pre-impingement air <NUM> because the spent cooling air <NUM> has removed heat from the combustion liner <NUM> during the impingement process.

Referring to the flow path of air exiting the impingement cooling apparatus <NUM>, as shown in <FIG>, pre-impingement air <NUM> exits each of the impingement members <NUM> via the plurality of impingement apertures <NUM> and impinges upon the interior surfaces <NUM>, <NUM> of the side walls <NUM>, <NUM>. At which point, the air undergoes an energy transfer by removing heat from the side walls <NUM>, <NUM> and thus becoming post-impingement air <NUM>. The post-impingement air <NUM> then reverses directions and flows through gaps <NUM> (<FIG>) defined between the impingement members <NUM>. As shown in <FIG>, the impingement cooling apparatus <NUM> may further define a collection passageway <NUM> that receives post-impingement air <NUM> from the gaps <NUM> defined between the impingement members <NUM>. Both the gaps <NUM> and the collection passageway <NUM> favorably provide a path for the post-impingement air <NUM> to travel away from the pre-impingement air <NUM>. This is advantageous because it prevents the post-impingement air <NUM> from impeding, i.e. flowing across and disrupting, the flow of pre-impingement air <NUM>, which allows the pre-impingement air <NUM> to maintain its high velocity and cool the walls <NUM>, <NUM> effectively. Once the post-impingement air <NUM> is within the collection passageway <NUM>, it may flow in a direction generally opposite to the axial direction A, i.e. opposite the direction of combustion gases. As shown in <FIG>, the post-impingement air <NUM> may flow from the collection passageway <NUM>, through the one or more holes defined in the rib <NUM>, around the pressure side fuel injector <NUM>, and into the inlet <NUM> of the suction side fuel injector <NUM>. In this way, all of the air that flows through impingement cooling apparatus <NUM> is utilized for both impingement cooling and combustion gas generation, which minimizes the amount of wasted air from the compressor section <NUM> and therefore increases the overall performance of the gas turbine <NUM>.

Referring now to the flow path of air exiting the cooling insert <NUM>, as shown in <FIG>, pre-impingement air <NUM> may exit the walls <NUM>, <NUM> via the plurality of impingement apertures <NUM>, <NUM> and impinge upon the interior surfaces <NUM>, <NUM> of the side walls <NUM>, <NUM>. At which point, the air undergoes an energy transfer by removing heat from the side walls <NUM>, <NUM> and thus becoming post-impingement air <NUM>. Then a portion post-impingement air <NUM> then changes directions and flows in a direction opposite to the axial direction A, i.e., opposite the direction of combustion gases. As shown in <FIG>, the post-impingement air <NUM> may then reverse directions and travel through a collection passageway <NUM>, that is defined between the walls <NUM>, <NUM>. The collection passageway <NUM> may direct the post impingement air <NUM> towards the pressure side fuel injector <NUM>. In this way, the collection passageway <NUM> favorably provides a path for the post-impingement air <NUM> to travel that is away from the pre-impingement air <NUM>. This is advantageous because it prevents the post-impingement air <NUM> from impeding, i.e., flowing across and disrupting, the flow of pre-impingement air <NUM>, which allows the pre-impingement air <NUM> to maintain its high velocity and cool the walls <NUM>, <NUM> effectively. Once the post-impingement air <NUM> is within the collection passageway <NUM>, it may be guided towards the inlet <NUM> of the pressure side fuel injector <NUM>. For example, the post-impingement air <NUM> may flow from the collection passageway <NUM>, through the one or more openings defined in the rib <NUM>, around the suction side fuel injector <NUM>, and into the inlet <NUM> of the pressure side fuel injector <NUM>. In this way, all of the air that flows through the cooling insert <NUM> is utilized for both impingement cooling and combustion gas generation, which minimizes the amount of wasted air from the compressor section <NUM> and therefore increases the overall performance of the gas turbine <NUM>.

<FIG> illustrates an enlarged cross-sectional view of a portion of the outer liner segment <NUM>, and <FIG> illustrates an enlarged cross-sectional view of a portion of the inner liner segment <NUM>, in accordance with exemplary embodiments of the integrated combustor nozzle <NUM>. In many embodiments, the integrated combustion nozzle <NUM> may include an outer impingement panel <NUM> and an inner impingement panel <NUM> on either side of the combustion liner <NUM>, in order to provide impingement cooling to the entire outer liner segment <NUM> and inner liner segment <NUM>.

As shown in <FIG> and <FIG>, both the outer impingement panel <NUM> and the inner impingement panel <NUM> may include an impingement plate <NUM> that is disposed along the exterior surfaces <NUM>, <NUM> of the outer liner segment <NUM> and the inner liner segment <NUM>, respectively. For example, the impingement plate <NUM> of the outer impingement panel <NUM> may be disposed along the exterior surface <NUM>, i.e. radially outer surface, of the outer liner segment <NUM>. Similarly, the impingement plate <NUM> of the inner impingement panel <NUM> may be disposed along the exterior surface <NUM>, i.e. radially inner surface, of the inner liner segment <NUM>. In exemplary embodiments, as shown, each impingement plate <NUM> may be spaced from the respective exterior surfaces <NUM>, <NUM> along the radial direction R to form a cooling flow gap <NUM> therebetween. For example, with respect to the outer impingement panels <NUM>, the impingement plates <NUM> may be spaced outwardly from the exterior surface <NUM> of the outer liner segment along the radial direction R, thereby forming the cooling flow gap <NUM> therebetween. Similarly, the impingement plates <NUM> of the inner impingement panels <NUM> may be spaced inward from the exterior surface <NUM> of the inner liner segment <NUM> along the radial direction R, thereby forming the cooling flow gap <NUM> therebetween.

As shown in <FIG> and <FIG>, the various arrows may represent the flow path of air within the impingement panels <NUM>, <NUM>. In exemplary embodiments, the high pressure plenum <NUM> may be in fluid communication with the cooling flow gap <NUM> via a plurality of impingement holes <NUM> that are defined through the impingement plates <NUM> along the radial direction R. Specifically, the impingement holes <NUM> may be sized and oriented to direct pre-impingement air <NUM> from the high pressure plenum <NUM> in discrete jets to impinge upon the exterior surface <NUM>, <NUM> of the outer liner segment <NUM> and the inner liner segment <NUM>. The discrete jets of pre-impingement air <NUM> may then impinge (or strike) the exterior surface <NUM>, <NUM> and create a thin boundary layer of air over the exterior surface <NUM>, <NUM>, which allows for optimal heat transfer between the liner segments <NUM>, <NUM> and the air. Once the air has impinged upon the exterior surface <NUM>, <NUM>, it may be referred to as "post-impingement air" and/or "spent cooling air" because the air has undergone an energy transfer and therefore has different characteristics. For example, the spent cooling air <NUM> may have a higher temperature and lower pressure than the pre-impingement air <NUM> because it has removed heat from the combustion liner segments <NUM>, <NUM> during the impingement process.

According to the invention, an inlet portion <NUM> extends from the impingement plate <NUM> to a collection duct <NUM>. As shown in <FIG>, the collection duct <NUM> defines a collection passage <NUM> that receives post impingement air <NUM> from the cooling flow gap <NUM> via the inlet portion <NUM> and guides the post impingement air <NUM> towards the low pressure inlet <NUM> of the cooling insert <NUM> to be utilized within the fuel injectors <NUM>, <NUM> (<FIG>). As shown in <FIG>, the inlet portion <NUM> may provide a passageway between the cooling flow gap <NUM> and the collection passage <NUM>. For example, the inlet portion <NUM> may extend directly from the impingement plate <NUM> to the collection duct <NUM>, such that the inlet portion <NUM> directly fluidly couples the cooling flow gap <NUM> to the collection passage <NUM>. As shown in <FIG>, the inlet portion <NUM> includes side walls <NUM> spaced apart from one another. The side walls <NUM> extend axially along the impingement plate <NUM>, parallel to one another, such that they define an elongated slot shaped opening <NUM> (<FIG>) through the impingement plate <NUM> for the passage of post-impingement air <NUM>.

In particular embodiments, as shown in <FIG>, each collection duct <NUM> may have a cross-sectional shape that defines a rectangular area. For example, each collection duct <NUM> may include a radially inward wall <NUM>, a radially outward wall <NUM>, and side walls <NUM> that extend between the radially inward wall <NUM> and the radially outward wall <NUM>. In particular embodiments, the side walls <NUM> of the collection duct <NUM> may be parallel to one another and longer than the radially inward/outward walls <NUM>, <NUM>, which advantageously allows the collection duct <NUM> to have a large collection area without overlapping the impingement holes <NUM> and causing an impediment to the airflow between the high pressure plenum <NUM> and the cooling flow gap <NUM>. In other embodiments (not shown), the collection duct may have any suitable cross sectional shape, such as a circle, oval, diamond, square, or other suitable polygonal shape, and should therefore not be limited to any particular cross sectional shape unless specifically recited in the claims.

As shown in <FIG>, the inlet portion <NUM> may define a first width <NUM> and the collection duct <NUM> may define a second width <NUM>. More specifically, the first width <NUM> may be defined between the side walls <NUM> of the inlet portion <NUM>. Similarly, the second width <NUM> of the collection duct <NUM> may be defined between the side walls <NUM> of the collection duct <NUM>. It may be advantageous to have the first width <NUM> be as small as possible relative to the second width <NUM> of the collection duct <NUM>, in order to maximize the amount of area that can be impingement cooled by the impingement plate <NUM>. For example, in exemplary embodiments, the second width <NUM> of the collection duct <NUM> may be larger than the first width <NUM> of the inlet portion <NUM>.

In many embodiments, as shown in <FIG>, the collection duct <NUM> may be a first collection duct <NUM>', and the impingement panel <NUM> may further include a second collection duct <NUM>" that extends from the impingement panel <NUM>. As shown, the first collection duct <NUM>' and the second collection duct <NUM>" may be spaced apart from one another and may extend generally parallel to one another in the axial direction A. In such embodiments, each collection duct <NUM>', <NUM>" may be coupled to the impingement plate <NUM> via respective inlet portions <NUM>, which provides a passageways between the cooling flow gap <NUM> and the collection passages <NUM>. For example, the respective inlet portions <NUM> may each extend directly from the impingement plate <NUM> to the collection duct <NUM>, such that they directly fluidly couple the cooling flow gap <NUM> to the respective collection passages <NUM>.

<FIG> illustrates a plan view along the radial direction R of two impingement panels <NUM> and a cooling insert <NUM> isolated from the other components of the integrated combustor nozzle. As shown in <FIG>, the impingement panels <NUM> may be representative of either or both of the outer impingement panel <NUM> and/or the inner impingement panel <NUM>. In many embodiments, each of the impingement panels <NUM> may couple to the low pressure inlet <NUM> of the cooling insert <NUM>. In particular embodiments, each of the collection ducts <NUM> may couple to the low pressure inlet <NUM> via a connection duct <NUM>. In some embodiments (not shown), the collection ducts <NUM> may couple directly to the respective low pressure inlets <NUM> of the cooling insert <NUM>. As discussed below in detail, the low pressure inlets <NUM> of the cooling insert <NUM> may be in direct fluid communication with the collection passageway <NUM>, and therefore in fluid communication with the suction side fuel injector <NUM>. In this way, the collection ducts <NUM> advantageously provide a passageway for post-impingement air <NUM> to travel to a fuel injector where they may be used to produce combustion gases within the secondary combustion zone <NUM>.

In many embodiments the impingent panels <NUM> may be a singular body that extends continuously from a forward end to an aft end. However, in exemplary embodiments, as shown in <FIG> the impingement panels <NUM> may include a plurality of panel segments <NUM> coupled to one another. For example, in many embodiments, the impingement panel <NUM> may include two panel segments <NUM>, such as a forward segment <NUM> and an aft segment <NUM> coupled together. In other embodiments, the impingement panel may include three or more segments, such as a forward segment <NUM>, a middle segment <NUM>, and an aft segment <NUM>. In such embodiments, the forward segment <NUM> and the aft segment <NUM> may each independently couple to the middle segment <NUM>, as shown. Dividing the impingement panels <NUM> into panel segments <NUM> may advantageously allow for an increased number of impingement panels <NUM> to be manufactured, such as through additive manufacturing, at one time, which can result in production cost savings.

As illustrated by the hidden lines in <FIG>, the inlet portion <NUM> of each of the panel sections <NUM> may further define an elongated slot opening <NUM> through the respective impingement plates <NUM> that allows post impingement air <NUM> to flow from the cooling gap into the collection duct <NUM>. In some embodiments (not shown), the elongated slot opening <NUM> may be continuous between the panel segments <NUM>.

In various embodiments, as shown in <FIG>, each of the collection ducts <NUM> may converge in cross sectional from a forward end <NUM> to an aft end <NUM>, i.e., in the axial direction A. More specifically, the side walls <NUM> of the collection duct <NUM> may converge towards one another from the forward end <NUM> to the aft end of the impingement panel <NUM>, thereby gradually reducing the second width <NUM> and the cross-sectional area of the collection duct <NUM> as it extends in the axial direction A. Gradually reducing the cross-sectional area of the collection duct <NUM> from a forward end <NUM> to an aft end <NUM> of the impingement panel <NUM> may favorably influence the post impingement air <NUM> to flow towards the cooling insert <NUM>, i.e., in a direction opposite the axial direction.

In operation, the collection duct <NUM> may receive spent cooling air from the cooling flow gap <NUM>. As used herein, the terms "post-impingement air" and/or "spent cooling air" refer to air that has already impinged upon a surface and therefore undergone an energy transfer. For example, the spent cooling air may have a higher temperature and lower pressure than prior to having impinged upon the exterior surface <NUM>, <NUM>, which makes the spent cooling air nonideal for further cooling within the integrated combustion nozzle. However, the collection duct <NUM> advantageously collects the spent cooling air and directs it towards one or more fuel injectors, e.g., the fuel injection module <NUM> and/or one or both fuel injectors <NUM> and <NUM>, for use in either the primary combustion zone <NUM> or the secondary combustion zone <NUM>. In this way, the impingement panel <NUM> efficiently utilizes air from the high pressure plenum <NUM> by first utilizing the air to cool the liner segments <NUM>, <NUM> and then using the air to produce combustion gases that power the turbine section <NUM>.

In many embodiments, each of the panel segments <NUM> may be integrally formed as a single component. That is, each of the subcomponents, e.g., the impingement plate <NUM>, the inlet portion <NUM>, the collection duct <NUM>, and any other subcomponent of the panel segments <NUM>, may be manufactured together as a single body. In exemplary embodiments, this may be done by utilizing the additive manufacturing system <NUM> described herein. However, in other embodiments, other manufacturing techniques, such as casting or other suitable techniques, may be used. In this regard, utilizing additive manufacturing methods, each panel segment <NUM> of the impingement panel <NUM> may be integrally formed as a single piece of continuous metal, and may thus include fewer sub-components and/or joints compared to prior designs. The integral formation of each panel segment <NUM> through additive manufacturing may advantageously improve the overall assembly process. For example, the integral formation reduces the number of separate parts that must be assembled, thus reducing associated time and overall assembly costs. Additionally, existing issues with, for example, leakage, joint quality between separate parts, and overall performance may advantageously be reduced. In some embodiments, the entire impingement panel <NUM> may be integrally formed as a single component.

<FIG> illustrates a cross sectional view of a panel segment <NUM> of the impingement panel <NUM> from along the axial direction A, and <FIG> illustrates plan view of a panel segment <NUM> from along the radial direction R, in accordance with embodiments of the present disclosure. It will be appreciated that the features of the panel segment <NUM> shown in <FIG> and <FIG> can be incorporated into any of the panel segments described herein, such as forward segment <NUM>, middle segment <NUM>, and/or the aft segment <NUM>.

As shown in <FIG> and <FIG>, the panel segment <NUM> further includes one or more supports <NUM> that extend between, and may be integrally formed with, the inlet portion <NUM>, the collection duct <NUM>, and the impingement plate <NUM>, in order to provide structural support thereto. In various embodiments, each support <NUM> may be shaped substantially as a flat plate that extends between the impingement plate <NUM> and the collection duct <NUM>. In particular embodiments, each support <NUM> may extend from a first end <NUM> integrally formed with to the impingement plate <NUM> to a second end <NUM> integrally formed with the collection duct <NUM>. In exemplary embodiments, the support <NUM> may be fixedly coupled to the panel segment <NUM>, e.g., the support <NUM> may be a separate component that is welded and/or brazed on to the panel segment <NUM>. Utilizing the supports <NUM> in this way provides additional structural integrity to the collection duct <NUM>, which may advantageously prevent damage to the impingement panel <NUM> caused from vibrational forces of the gas turbine <NUM> during operation.

In particular embodiments, each of the supports <NUM> includes a first side <NUM> and a second side <NUM> that extend between the first end <NUM> and the second end <NUM> of each of the supports <NUM>, i.e., between the impingement plate <NUM> and the collection duct <NUM>. As shown in <FIG>, the first end <NUM>, second end <NUM>, first side <NUM>, and second side <NUM> may collectively define the perimeter of the support <NUM>. In many embodiments, the first side <NUM> of the support <NUM> extends along and is integrally formed with one of the side walls <NUM> of the inlet portion <NUM>. In exemplary embodiments, the second side <NUM> of the support <NUM> may be a generally straight line that extends from the impingement plate <NUM> at an angle <NUM>.

For example, in many embodiments, the second side <NUM> of each support <NUM> may form an angle <NUM> of between about <NUM>° and about <NUM>° with the impingement plate <NUM>. In other embodiments, the second side <NUM> of each support <NUM> may form an angle <NUM> of between about <NUM>° and about <NUM>° with the impingement plate <NUM>. In various embodiments, the second side <NUM> of each support <NUM> may form an angle <NUM> of between about <NUM>° and about <NUM>° with the impingement plate <NUM>. In particular embodiments, the second side <NUM> of each support <NUM> may form an angle <NUM> of between about <NUM>° and about <NUM>° with the impingement plate <NUM>.

In exemplary embodiments, the angle <NUM> of the second side <NUM> may advantageously provide additional structural support to the impingement panel <NUM>, thereby preventing vibrational damage to the impingement panel <NUM> during operation of the gas turbine <NUM>. In addition, the angle <NUM> of the second side <NUM>, may provide additional structural support to the collection duct <NUM> during the additive manufacturing process of the impingement panel <NUM>, which advantageously reduces the likelihood of distortion and/or defects in the impingement panel <NUM>. For example, the angle <NUM> of the second side <NUM> relative to the impingement plate <NUM> discussed herein may prevent the support <NUM> from overhanging, i.e. having excessive thick-to-thin variation, while being fabricated using the additive manufacturing system <NUM> (<FIG>). As a result, the impingement panel <NUM>, which would otherwise be difficult to manufacture via traditional means due to its complex geometry, may be fabricated using an additive manufacturing system <NUM> without causing defects or deformations in the part.

As shown in <FIG>, the each of the supports <NUM> may form an angle <NUM> with the inlet portion <NUM> (shown as dashed lines in <FIG>). More specifically, each of the supports <NUM> may form the angle <NUM> with the side wall <NUM> of the inlet portion <NUM>. In many embodiments, the angle <NUM> may be oblique, which favorably allows the support <NUM> to extend further along the impingement plate <NUM>. However, in other embodiments (not shown), the one or more of the supports <NUM> may be perpendicular to the inlet portion <NUM>.

In various embodiments, the angle <NUM> between the side wall <NUM> of the inlet portion <NUM> and the support <NUM> may be between about <NUM>° and about <NUM>°. In other embodiments, the angle <NUM> between the side wall <NUM> of the inlet portion <NUM> and the support <NUM> may be between about <NUM>° and about <NUM>°. In particular embodiments, the angle <NUM> between the side wall <NUM> of the inlet portion <NUM> and the support <NUM> may be between about <NUM>° and about <NUM>°. In many embodiments, the angle <NUM> between the side wall <NUM> of the inlet portion <NUM> and the support <NUM> may be between about <NUM>° and about <NUM>°.

As shown in <FIG>, the panel segment <NUM> may further include center axis <NUM>, which may be generally parallel to the side walls <NUM> of the inlet portion <NUM>. In many embodiments, when the panel segment <NUM> is installed in an integrated combustor <NUM>, the center axis <NUM> may extend coaxially with the axial direction A the gas turbine <NUM>. In other embodiments, the center axis <NUM> may extend generally parallel to the axial direction A, when the panel segment is installed in an integrated combustor nozzle <NUM>.

<FIG> illustrates a cross-sectional perspective view of a panel segment <NUM>, in accordance with embodiments of the present disclosure. The panel segment <NUM> may extend from a first end <NUM>, along the center axis <NUM> (<FIG>), to a second end <NUM>. <FIG> illustrates a plan view of an exemplary embodiment of the first end <NUM> of the panel segment <NUM> from along the center axis <NUM>, and <FIG> illustrates the second end <NUM> of the panel segment <NUM> from along the center axis <NUM>.

As shown in <FIG>, the first end <NUM> of the panel segment <NUM> includes a flange <NUM> that extends from the impingement panel. In various embodiments, the flange <NUM> may be a generally flat plate that extends from first end <NUM> of the panel segment <NUM>. More specifically, the flange <NUM> may be perpendicular to, and extend away from, the impingement plate <NUM>, the inlet portion <NUM>, and the collection duct <NUM> at the first end <NUM> of the panel segment <NUM>, in order to define a connection surface <NUM> (<FIG>). The connection surface <NUM> advantageously allows multiple panel segments <NUM> to be fixedly coupled together, by a means such as welding, brazing, or other suitable methods. In many embodiments, the flange <NUM> may also increase the overall rigidity and structural integrity of the panel segment <NUM>, thereby preventing vibrational damage that could be caused to the component during operation of the gas turbine <NUM>.

In many embodiments, the flange <NUM> may be integrally formed with the panel segment <NUM>, such that the collection plate <NUM>, the inlet portion <NUM>, the collection duct <NUM>, and the flange <NUM> may be a single piece of continuous metal. In such embodiments, the flange <NUM> may also provide manufacturing advantages. For example, the flange <NUM> generally surrounds the features of the panel segment <NUM> and provides additional structural support for the collection duct <NUM> during the additive manufacturing process.

As shown in <FIG>, in some embodiments, the second end <NUM> of the impingement panel <NUM> may not include the flange <NUM> that is integrally formed therewith, as is the case with the first end <NUM>. As indicated by the dashed line in <FIG>, an end plate <NUM> may be attached to the second end <NUM> and fixedly coupled thereto. For example, the end plate <NUM> may be an entirely separate component from the impingement panel segment <NUM>. In many embodiments, the end plate <NUM> may be welded or brazed to the second end <NUM> after the manufacturing of the impingement panel segment <NUM> is complete. The end plate <NUM>, which is fixedly coupled to the second end <NUM>, may have a substantially similar geometry as the flange <NUM>, but is a separate component rather than being integrally formed. The end plate <NUM> may function to couple the second end <NUM> of the impingement panel segment <NUM> to the first end <NUM> of a neighboring impingement panel segment (as shown in <FIG>). In exemplary embodiments, the end plate <NUM> of an impingent panel segment <NUM> may be fixedly coupled to the flange <NUM> of a neighboring impingement panel segment <NUM>. Coupling the impingement panel segments <NUM> in this way may be advantageous because the end plate <NUM> and the flange <NUM> are relatively flat and smooth surfaces that provide for an easy and error free weld therebetween. In other embodiments, both the first end <NUM> and the second end <NUM> may include a flange <NUM>, in which the flange <NUM> of the first end <NUM> of a panel segment <NUM> may fixedly couple to the flange <NUM> of the second end <NUM> of a neighboring panel segment <NUM>.

To illustrate an example of an additive manufacturing system and process, <FIG> shows a schematic/block view of an additive manufacturing system <NUM> for generating an object <NUM>, such as the panel segments <NUM>, the cooling insert <NUM>, and/or the impingement cooling apparatus <NUM> described herein. <FIG> may represent an additive manufacturing system configured for direct metal laser sintering (DMLS) or direct metal laser melting (DMLM). The additive manufacturing system <NUM> fabricates objects, such as the object <NUM> (which may be representative of the panel segments <NUM>, the cooling insert <NUM>, and/or the impingement cooling apparatus <NUM> described herein). For example, the object <NUM> may be fabricated in a layer-by-layer manner by sintering or melting a powder material (not shown) using an energy beam <NUM> generated by a source such as a laser <NUM>. The powder to be melted by the energy beam is supplied by reservoir <NUM> and spread evenly over a build plate <NUM> using a recoater arm <NUM> to maintain the powder at a level <NUM> and remove excess powder material extending above the powder level <NUM> to waste container <NUM>. The energy beam <NUM> sinters or melts a cross sectional layer of the object being built under control of the galvo scanner <NUM>. The build plate <NUM> is lowered and another layer of powder is spread over the build plate and the object being built, followed by successive melting/sintering of the powder by the laser <NUM>. The process is repeated until the object <NUM> is completely built up from the melted/sintered powder material. The laser <NUM> may be controlled by a computer system including a processor and a memory. The computer system may determine a scan pattern for each layer and control laser <NUM> to irradiate the powder material according to the scan pattern. After fabrication of the object <NUM> is complete, various post-processing procedures may be applied to the object <NUM>. Post processing procedures include removal of excess powder by, for example, blowing or vacuuming. Other post processing procedures include a stress release process. Additionally, thermal and chemical post processing procedures can be used to finish the object <NUM>.

<FIG> is a flow chart of a sequential set of steps <NUM> through <NUM>, which define a method <NUM> of fabricating an impingement panel (such as one of the impingement panels <NUM>, <NUM>, <NUM> described herein), in accordance with embodiments of the present disclosure. The method <NUM> may be performed using an additive manufacturing system, such as the additive manufacturing system <NUM> described herein or another suitable system. As shown in <FIG>, the method <NUM> includes a step <NUM> of irradiating a layer of powder in a powder bed <NUM> to form a fused region. In many embodiments, as shown in <FIG>, the powder bed <NUM> may be disposed on the build plate <NUM>, such that the fused region is fixedly attached to the build plate <NUM>. The method <NUM> may include a step <NUM> of providing a subsequent layer of powder over the powder bed <NUM> from a first side of the powder bed <NUM>. The method <NUM> further includes a step <NUM> of repeating steps <NUM> and <NUM> until the impingement panel is formed in the powder bed <NUM>.

<FIG> illustrates a perspective view of the impingement cooling apparatus <NUM>, which is isolated from the integrated combustor nozzle and positioned on a build plate <NUM>, and in which one of the impingement members in a row has been cut away. As discussed below, the impingement cooling apparatus <NUM> may be additively manufactured on a build plate <NUM>, e.g., by the additive manufacturing system <NUM>. <FIG> depicts the impingement cooling apparatus <NUM> prior to removal from the build plate <NUM> and installation into the integrated combustor nozzle <NUM>, in accordance with embodiments of the present disclosure.

As shown in <FIG>, the impingement cooling apparatus <NUM> may extend in the radial direction R, which may coincide with the build direction, from a first end <NUM> to a second end <NUM>. In many embodiments, the impingement cooling apparatus <NUM> includes a plurality of impingement members <NUM>, which are arranged in a first row <NUM> of impingement members <NUM> and a second row <NUM> of impingement members <NUM>. Each impingement member <NUM> in the first row <NUM> of impingement members <NUM> may extend from a first flange <NUM> at the first end <NUM> to a respective closed end <NUM> at the second end <NUM> of the impingement cooling apparatus <NUM>. Similarly, each impingement member <NUM> in the second row <NUM> of impingement members <NUM> may extend from a second flange <NUM> at the first end <NUM> to a respective closed end <NUM> at the second end <NUM> of the impingement cooling apparatus <NUM>. In this way, the first row <NUM> and the second row <NUM> of impingement members <NUM> may each be singular components capable of movement relative to one another during installation into the cavity <NUM>, which advantageously allows the distance between the rows <NUM>, <NUM> of impingement members <NUM> and the walls <NUM>, <NUM> to be independently set from one another.

In other embodiments, each impingement member <NUM> may be its own entirely separate component, which is capable of movement relative to the other impingement members <NUM> in the impingement cooling apparatus <NUM>. In such embodiments, each impingement member <NUM> may extend from a respective flange. In embodiments where each impingement member <NUM> is a separate component, the impingement members may be installed individually within the integrated combustor nozzle (i.e. one at a time), and each standoff <NUM>, <NUM> may serve to ensure that a properly sized gap is disposed between each impingement member <NUM> during both the installation of the impingement members <NUM> and the operation thereof.

In exemplary embodiments, each of the impingement members <NUM> may be substantially hollow bodies that extend from a respective opening <NUM> defined in the flanges <NUM>, <NUM> to a respective closed end <NUM> (<FIG>). Although the embodiment in <FIG> shows an impingement cooling apparatus <NUM> having eleven impingement cooling members <NUM>, the impingement cooling apparatus <NUM> may have any number of impingement members <NUM>, e.g., <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, or more. In various embodiments, as shown in <FIG>, each impingement member <NUM> in the plurality of impingement members <NUM> may be spaced apart from directly neighboring impingement members <NUM>, in order to define the gap <NUM> for post-impingement air <NUM> to flow between impingement members <NUM> and into the collection passageway <NUM> (<FIG>). In many embodiments, a plurality of impingement apertures <NUM> may be defined on each impingement member <NUM> of the plurality of impingement members <NUM>.

<FIG> depicts an enlarged cross-sectional view of the integrated combustor nozzle <NUM> from along the radial direction R, in which the impingement cooling apparatus <NUM> is positioned within the cavity <NUM>. As shown in <FIG>, the integrated combustor nozzle <NUM> may further include a camber axis <NUM>, which may be defined halfway between the pressure side wall <NUM> and the suction side wall <NUM>. For example, the camber axis <NUM> may be curved and/or contoured to correspond with the curve of the pressure side wall <NUM> and the suction side wall <NUM>. A transverse direction T may be defined orthogonally with respect to the camber axis <NUM>. More specifically, the transverse direction T may extend outward from, and perpendicular to, a line that is tangent to the camber axis <NUM> at each location along the camber axis <NUM>.

In particular embodiments, each impingement member <NUM> of the plurality of impingement members <NUM> includes an impingement wall <NUM> spaced apart from a solid wall <NUM>. In exemplary embodiments, the plurality of impingement apertures may be defined on the impingement wall <NUM>, in order to direct pre-impingement air <NUM> towards the interior surface <NUM>, <NUM> of the walls <NUM>, <NUM> (<FIG>). The solid wall <NUM> may be oppositely disposed from the impingement wall <NUM>. In many embodiments, the solid wall <NUM> of each respective impingement member <NUM> may be directly outward of the camber axis <NUM> along the transverse direction T, such that solid walls <NUM> of the impingement member <NUM> collectively define the boundary of the collection passageway <NUM>. As used herein, the term "solid" may refer to a wall or walls that are impermeable, such that they do not allow air or other fluids to pass therethrough. For example, the each of the solid walls <NUM> may not have any impingement apertures, holes, or voids that would allow for pre-impingement air <NUM> to escape, in order to ensure all of the air gets directed towards the interior surface <NUM>, <NUM> of the walls <NUM>, <NUM> for cooling.

In particular embodiments, as shown in <FIG>, the plurality of impingement members <NUM> may include a first row <NUM> of impingement members <NUM> disposed proximate the pressure side wall <NUM> and a second row <NUM> of impingement members <NUM> disposed proximate the suction side wall <NUM>. For example, the first row <NUM> and the second row <NUM> of impingement members may be disposed on opposite sides of the camber axis <NUM>, such that they are spaced apart in the transverse direction T. As shown in <FIG>, the collection passageway <NUM> may be defined between the first row <NUM> and the second row <NUM> of impingement members <NUM>. More specifically, the collection passageway <NUM> may be defined collectively between the solid walls <NUM> of the first row <NUM> of impingement members <NUM> and the solid walls <NUM> of the second row <NUM> of impingement members <NUM>. As shown in <FIG> and discussed above, the collection passageway <NUM> may function to receive post impingement air <NUM> and direct it towards a fuel injector, such as the suction side fuel injector <NUM> (<FIG>).

In particular embodiments, the first row <NUM> of impingement members <NUM> and the second row <NUM> of impingement members diverge away from each other from an aft end <NUM> to a forward end <NUM> of impingement cooling apparatus <NUM>, i.e., opposite the direction of combustion gases within the combustion zones <NUM>, <NUM>. For example, the first row <NUM> of impingement members <NUM> and the second row <NUM> of impingement members diverge away from each other in the transverse direction from an aft end <NUM> to a forward end <NUM> of impingement cooling apparatus <NUM>. In this way, the transverse distance between impingement members <NUM> of the first row <NUM> and impingement members <NUM> of the second row <NUM> may gradually increase from the aft end <NUM> to the forward end <NUM>, thereby influencing post-impingement air <NUM> to travel towards the suction side fuel injector <NUM>.

As shown in <FIG>, the impingement wall <NUM> of each respective impingement member <NUM> on the first row <NUM> may be contoured to correspond with a portion of pressure side wall <NUM>, such that the impingement walls <NUM> of the first row <NUM> collectively correspond to the contour of the pressure side wall <NUM>. Similarly, the impingement wall <NUM> of each respective impingement member <NUM> on the second row <NUM> may be contoured to correspond with a portion of the suction side wall <NUM>, such that the impingement walls <NUM> of the second row <NUM> collectively correspond to the contour of the suction side wall <NUM>. Matching the contour of the walls <NUM>, <NUM> advantageously maintains a desired transverse distance from the respective walls <NUM>, <NUM>. In many embodiments, the transverse distance between the impingement walls <NUM> and the respective walls <NUM>, <NUM> may be generally constant.

In particular embodiments, each impingement member <NUM> of the plurality of impingement members <NUM> may include a first solid side wall <NUM> and a second solid side wall <NUM> that each extend between the impingement wall <NUM> and the solid wall <NUM>. As shown in <FIG>, the first solid side wall <NUM> and the second solid side wall <NUM> of each impingement member <NUM> may be spaced apart and oppositely disposed from one another. In various embodiments, the first solid wall <NUM> and second side wall <NUM> of each impingement member <NUM> may be generally parallel to one another in the transverse direction T. As shown in <FIG>, the first solid side wall <NUM>, the second solid wall <NUM>, the impingement wall <NUM>, and the solid wall <NUM> of each impingement member of the plurality of impingement members collectively defines an internal volume <NUM> that is in fluid communication with the high pressure plenum <NUM>. In exemplary embodiments, each of the impingement members <NUM> may define a generally rectangular cross-sectional area. However, in other embodiments (not shown), the each of the impingement members <NUM> may define a cross sectional area having a circular shape, a diamond shape, a triangular shape, or other suitable cross-sectional shapes.

In particular embodiments, as shown in <FIG>, <FIG> and <FIG>, a gap <NUM> may be defined between directly neighboring impingement members <NUM>, which advantageously provides a path for post impingement air <NUM> to travel into the collection passageway <NUM>. In various embodiments, each of the gaps <NUM> may be defined directly between the first side wall <NUM> of an impingement member and the second side wall <NUM> of a directly neighboring impingement member <NUM>. In this way, each impingement member <NUM> of the plurality of impingement members <NUM> partially defines at least one gap <NUM>. As shown in <FIG>, each of the gaps <NUM> may be defined between the first side wall <NUM> of an impingement member <NUM> and the second side wall <NUM> of a neighboring impingement member <NUM> in a direction generally parallel to the camber axis <NUM> at their respective locations. In other embodiments (not shown), each impingement member <NUM> may define a diamond shaped cross-sectional area. In such embodiments, the first side wall <NUM> and the second side wall <NUM> may be angled relative to the camber axis, which may advantageously reduce the pressure drop of the impingement air.

<FIG> depicts a cross-sectional view of a single impingement member <NUM> from along the camber axis <NUM>. <FIG> illustrates an enlarged cross-sectional view of an impingement member <NUM> and a portion of two neighboring impingement members <NUM> from along the radial direction R, in accordance with embodiments of the present disclosure. It should be appreciated that the features of impingement member <NUM> shown in <FIG> and <FIG> may be incorporated into any of the impingement members <NUM> in the plurality of impingement members <NUM> described herein. In exemplary embodiments, as shown in <FIG> and <FIG>, the impingement member <NUM> may further include a first protrusion <NUM>, a second protrusion <NUM>, and a plurality of cross-supports <NUM> extending therebetween. In many embodiments, the first protrusion may <NUM> be disposed on the impingement wall <NUM>, the second protrusion <NUM> may be disposed on the solid wall <NUM>, and the plurality of cross-supports <NUM> may each extend from the first protrusion <NUM>, through the internal volume <NUM>, to the second protrusion <NUM>. Each of the protrusions <NUM>, <NUM> may extend from the respective walls <NUM>, <NUM> towards an axial centerline <NUM> (<FIG>) of the impingement member <NUM>. More specifically, the first protrusion <NUM> may extend directly from an interior surface <NUM> of the impingement wall <NUM> towards the axial centerline <NUM>. Likewise, the second protrusion <NUM> may extend directly from an interior surface <NUM> of the solid wall <NUM> towards the axial centerline <NUM>. In various embodiments, the first protrusion <NUM> may extend radially along the entire length of the impingement wall <NUM>, e.g., between the open end <NUM> and the closed end <NUM> of the impingement member <NUM>.

In particular embodiments, as shown in <FIG>, each protrusion <NUM>, <NUM> may include first portion <NUM> that extends generally perpendicularly between the respective walls <NUM>, <NUM> and a second portion <NUM>. The second portion <NUM> of each protrusion <NUM>, <NUM> may extend generally perpendicularly to the respective first portions <NUM>, such that the protrusions <NUM>, <NUM> each define a T-shaped cross section. The protrusions <NUM>, <NUM> advantageously improve the rigidity of each of the impingement members <NUM>, and therefore they improve the rigidity of the overall impingement cooling apparatus <NUM>. Increased rigidity of the impingement cooling apparatus <NUM> may prevent damage caused by vibrational forces of the gas turbine <NUM> during operation. For example, the protrusions <NUM>, <NUM> may give the impingement cooling apparatus <NUM> a more desirable natural frequency, in order to prevent failures of the impingement cooling apparatus <NUM> caused by minute oscillations of the integrated combustion nozzle <NUM>.

As shown in <FIG> and <FIG>, each of the cross-supports <NUM> may include a first support <NUM> bar and a second support bar <NUM>, which intersect with one another at an intersection point <NUM> (<FIG>) disposed within the internal volume <NUM> of the impingement member <NUM>. In particular embodiments, the first support bar <NUM> and the second support bar <NUM> of each of the cross-supports <NUM> may extend between the first protrusion <NUM> and the second protrusion <NUM>. More specifically, the first support bar <NUM> and the second support bar <NUM> of each of the cross-supports <NUM> may extend directly between the second portions <NUM> of the first protrusion <NUM> and the second portion <NUM> of the second protrusion <NUM>. In other embodiments (not shown), the first support bar <NUM> and the second support bar <NUM> of each of the cross-supports may extend directly between the interior of the impingement wall and the interior of the solid wall, such that there are no protrusions present.

In many embodiments, as shown in <FIG>, the first support bar <NUM> and the second support bar may each form an angle <NUM> with the flange <NUM> that is oblique, i.e., not parallel or perpendicular. For example, in some embodiments, the first support bar <NUM> and the second support bar <NUM> may each form an angle <NUM> with the flange <NUM> that is between about <NUM>° and about <NUM>°. In other embodiments, the first support bar <NUM> and the second support bar <NUM> may each form an angle <NUM> with the flange <NUM> that is between about <NUM>° and about <NUM>°. In various embodiments, the first support bar <NUM> and the second support bar <NUM> may each form an angle <NUM> with the flange <NUM> that is between about <NUM>° and about <NUM>°. In particular embodiments, the first support bar <NUM> and the second support bar <NUM> may each form an angle <NUM> with the flange <NUM> that is between about <NUM>° and about <NUM>°. The angle <NUM> advantageously provide additional structural integrity and internal bracing to each of the impingement members <NUM>, which prevents damage due to the vibrational forces of the gas turbine <NUM>. Additionally, as discussed below, the angle <NUM> of the support bars <NUM>, <NUM> allows the impingement members <NUM> to be additively manufactured without defects or deformation. For example, when being additively manufactured layer by layer, such as with the additive manufacturing system <NUM> described herein, the angle of the support bars <NUM>, <NUM> advantageously prevents the cross-supports <NUM> from otherwise detrimental overhang, which could cause deformation and/or a total collapse of the component. For example, a support bar extending perpendicularly across the impingement member <NUM> may be difficult and/or impossible to manufacture using an additive manufacturing system. Thus, the angle <NUM> between the support bars <NUM>, <NUM> and the flange <NUM> is favorable.

In many embodiments, as shown in <FIG> collectively, the impingement cooling apparatus <NUM> may further include stand-offs <NUM>, <NUM> that extend from each of the impingement members <NUM>. The stand-offs <NUM>, <NUM> may be shaped as substantially flat plates that extend outwardly from the impingement members <NUM>. In many embodiments, the stand-offs may space apart each impingement member <NUM> from surrounding surfaces, such as neighboring impingement members <NUM> and/or the walls <NUM>, <NUM> of the combustion liner <NUM>. The stand-offs <NUM>, <NUM> may be configured to keep the impingement members <NUM> at the desired distance from the surrounding surfaces, in order to optimize the impingement cooling of the combustion liner <NUM> and the recirculation of the post impingement air <NUM> into the collection passageway <NUM>.

In particular embodiments, the stand-offs may include side wall stand-offs <NUM> and impingement wall stand-offs <NUM>. As shown in <FIG>, in many embodiments, at least one side wall stand-off <NUM> and at least one impingement wall stand-off <NUM> may be disposed proximate the flange <NUM>, <NUM> on each impingement member <NUM>. in various embodiments, at least one side wall stand-off <NUM> and at least one impingement wall stand-off <NUM> may disposed proximate the closed end <NUM> of each impingement member <NUM> of the plurality of impingement members <NUM>. Arranging the stand-offs <NUM>, <NUM> proximate the first end <NUM> and second end <NUM> of the impingement cooling apparatus <NUM> may advantageously provide more uniform support and spacing between neighboring impingement members <NUM> and between impingement members <NUM> and the walls <NUM>, <NUM> of the combustion liner <NUM>.

In particular embodiments, as shown in <FIG>, the side wall stand-offs <NUM> may each extend from and couple the first solid side wall <NUM> of an impingement member <NUM> to the second solid side wall <NUM> of a neighboring impingement member <NUM>. In exemplary embodiments, the length of the side wall stand-offs <NUM> may set the distance of the gap <NUM> and may couple adjacent impingement members <NUM> together. For example, the impingement members <NUM> in a row, e.g. the first row <NUM> and/or second row <NUM>, may be linked to the neighboring impingement members <NUM> within that row via one or more of the side wall stand-offs <NUM>. In this way, the side wall stand-offs <NUM> function to maintain adequate space between the impingement members <NUM>. In addition, the side wall stand-offs <NUM> advantageously prevent deformation of the relatively slender impingement members <NUM> during the additive manufacturing process by providing additional structural support to the impingement cooling apparatus <NUM>.

In various embodiments, as shown in <FIG>, The impingement wall stand-offs <NUM> may function to maintain adequate space between the impingement members <NUM> and one of the walls <NUM>, <NUM> of the combustion liner <NUM>. For example, in exemplary embodiments, the impingement wall stand-offs <NUM> may extend from the impingement wall <NUM> and contact one of the walls <NUM>, <NUM> of the combustion liner <NUM>, which may be one of the first side wall <NUM> or the second side wall <NUM> of the combustion liner <NUM>. For example, unlike the side wall stand-offs <NUM>, the impingement wall stand-offs <NUM> are not coupled on both ends, but they are integrally formed with the impingement wall <NUM> on one end and in contact with the interior surface of either the pressure side wall <NUM> or the suction side wall <NUM> once the impingement cooling apparatus <NUM> is installed into the combustion liner <NUM>. In this way, the impingement wall stand-offs <NUM> may be removably coupled to the combustion liner <NUM>. In exemplary embodiments, the length of the side wall stand-offs <NUM> may set the distance of the gap disposed between the impingement wall <NUM> and the wall <NUM> or <NUM> of the combustion liner <NUM>.

<FIG> illustrate an enlarged view of an impingement wall stand-off <NUM> extending from an impingement wall <NUM> of an impingement member <NUM> to one of the walls <NUM>, <NUM> of the combustion liner <NUM> (shown as a dashed line), in accordance with embodiments of the present disclosure. More specifically, <FIG> illustrates an impingement wall stand-off <NUM> immediately after being manufactured, e.g., by the additive manufacturing system <NUM>, but prior to any post machining. In many embodiments, each of the impingement wall stand-offs may be manufactured having excess material or length <NUM>, as illustrated by the length <NUM> of the stand-off <NUM> that extends beyond the wall <NUM> or <NUM>. As shown in <FIG>, the excess material or length <NUM> of the stand-off <NUM> may be removed, in order to maintain the desired tolerance between the impingement wall <NUM> and the wall <NUM>, <NUM> for optimal cooling performance.

Although <FIG> illustrates an exemplary embodiment of an impingement wall stand-off <NUM> of the impingement cooling apparatus <NUM>, <FIG> may be representative of the various other stand-offs disclosed herein (such as the stand-offs disposed on the impingement panel <NUM> and/or the stand-offs disposed on the cooling insert <NUM>).

In particular embodiments, each row of impingement members <NUM>, <NUM> in the impingement cooling apparatus <NUM> may be integrally formed as a single component. That is, each of the subcomponents, e.g., one of the flanges <NUM>, <NUM>, the impingement members <NUM>, the first protrusion <NUM>, the second protrusion <NUM>, the plurality of cross supports346, the stand-offs <NUM>, <NUM>, and any other subcomponent of each row <NUM>, <NUM> of impingement members <NUM>, may be manufactured together as a single body. In exemplary embodiments, this may be done by utilizing the additive manufacturing system <NUM> described herein. However, in other embodiments, other manufacturing techniques, such as casting or other suitable techniques, may be used. In this regard, utilizing additive manufacturing methods, each row <NUM>, <NUM> of impingement members <NUM> may be integrally formed as a single piece of continuous metal, and may thus include fewer sub-components and/or joints compared to prior designs. The integral formation of each row <NUM>, <NUM> of impingement members <NUM> through additive manufacturing may advantageously improve the overall assembly process. For example, the integral formation reduces the number of separate parts that must be assembled, thus reducing associated time and overall assembly costs. Additionally, existing issues with, for example, leakage, joint quality between separate parts, and overall performance may advantageously be reduced. In some embodiments (not shown), the entire impingement cooling apparatus <NUM> may be integrally formed as a single component. In such embodiments, the impingement cooling apparatus may have a single flange, rather than a first flange <NUM> and a second flange <NUM>, from which all of the impingement members <NUM> extend.

<FIG> is a flow chart of a sequential set of steps <NUM> through <NUM>, which define a method <NUM> of fabricating an impingement cooling apparatus <NUM>, in accordance with embodiments of the present disclosure. The method <NUM> may be performed using an additive manufacturing system, such as the additive manufacturing system <NUM> described herein or another suitable system. As shown in <FIG>, the method <NUM> includes a step <NUM> of irradiating a layer of powder in a powder bed <NUM> to form a fused region. In many embodiments, as shown in <FIG>, the powder bed may be disposed the build plate <NUM>, such that the fused region is fixedly attached to the build plate <NUM>. The method <NUM> may include a step <NUM> of providing a subsequent layer of powder over the powder bed <NUM> from a first side of the powder bed <NUM>. The method <NUM> further includes a step <NUM> of repeating steps <NUM> and <NUM> until the impingement cooling apparatus <NUM> is formed in the powder bed <NUM>.

<FIG> illustrates a perspective view of a cooling insert <NUM>, which is isolated from the other components of the integrated combustor nozzle <NUM>, in accordance with embodiments of the present disclosure. As shown in <FIG>, the cooling insert <NUM> may extend between a first end <NUM> and a second end <NUM>. In many embodiments, the cooling insert <NUM> includes a flange <NUM> that extends between and generally surrounds the walls <NUM>, <NUM> at the first end <NUM> of the cooling insert <NUM>. In many embodiments, the flange <NUM> may define one or more openings that provide fluid communication between cooling insert <NUM>, the high pressure plenum <NUM>, and/or one or more of the impingement panels <NUM> described herein. In various embodiments, the flange <NUM> may couple the cooling insert <NUM> to one of the inner liner segment <NUM> or the outer liner segment <NUM>. As discussed below in more detail, the flange <NUM> may define both the first open end <NUM> and the second open end <NUM>, in order to provide fluid communication between the high pressure plenum <NUM> and the first wall and second wall of the cooling insert <NUM>. In this way, the first open end <NUM> and the second open <NUM> end defined within the flange <NUM> may serve as a high pressure air inlet. In many embodiments, the cooling insert <NUM> may further include a low pressure inlet <NUM> defined within the flange <NUM>. As shown best in <FIG> and <FIG>, the low pressure inlet <NUM> may provide for fluid communication between the collection ducts <NUM> of the impingement panels <NUM> and the collection passageway <NUM> of the cooling insert <NUM> (<FIG>).

<FIG> illustrates a cross-sectional view of a cooling insert <NUM> from along the axial direction A, <FIG> illustrates a cross-sectional view from along the radial direction R, and <FIG> illustrates a cross-sectional of a cooling insert <NUM> from along the circumferential direction C, in accordance with embodiments of the present disclosure. As shown in <FIG>, the cooling insert <NUM> may include an axial centerline <NUM> that extends between the walls <NUM>, <NUM> of the cooling insert. In exemplary embodiments, when the cooling insert <NUM> is installed into an integrated combustor nozzle <NUM>, the axial centerline <NUM> may coincide with the radial direction R of the gas turbine <NUM>.

As shown in <FIG>, the cooling insert <NUM> may include a first wall <NUM> that defines a first passage <NUM> therein. As shown, the first wall <NUM> may extend generally radially from a first open end <NUM> defined within the flange <NUM> to a first closed end <NUM>. In this way, the first wall <NUM> may be a substantially hollow body that receives air from the high pressure plenum <NUM> via the first open end <NUM> defined in the flange <NUM>. In particular embodiments, the first wall <NUM> includes a first impingement side <NUM> spaced apart from a first solid side <NUM>. As shown, the first passage <NUM> may be defined directly between the first impingement side <NUM> and the first solid side <NUM>. In various embodiments, the first impingement side <NUM> may define a first plurality of impingement apertures <NUM>, which may be configured to direct air from the first passage <NUM> towards the first side wall (e.g. the pressure side wall <NUM>) of the combustion liner <NUM> (<FIG>). In many embodiments, the first plurality of impingement apertures <NUM> may be sized and oriented to direct the pre-impingement air <NUM> in discrete jets to impinge upon the interior surface <NUM> of the pressure side wall <NUM>. The discrete jets of air impinge (or strike) the interior surface <NUM> and create a thin boundary layer of air over the interior surface <NUM> which allows for optimal heat transfer between the pressure side wall <NUM> and the air.

Similarly, the cooling insert <NUM> may further include a second wall <NUM> spaced apart from the first wall <NUM>. In many embodiments, the second wall <NUM> may define a second passage <NUM> therein. As shown, the first wall <NUM> may extend generally radially from a second open end <NUM> defined within the flange <NUM> to a second closed end <NUM>. In this way, the second wall <NUM> may be a substantially hollow body that receives air from the high pressure plenum <NUM> via the second open end <NUM> defined in the flange <NUM>. In particular embodiments, the second wall <NUM> includes a second impingement side <NUM> spaced apart from a second solid side <NUM>. As shown, the second passage <NUM> may be defined directly between the second impingement side <NUM> and the second solid side <NUM>. In various embodiments, the second impingement side <NUM> may define a second plurality of impingement apertures <NUM>, which may be configured to direct air from the second passage <NUM> towards the second side wall (e.g. the suction side wall <NUM>) of the combustion liner <NUM> (<FIG>). In many embodiments, the second plurality of impingement apertures <NUM> may be sized and oriented to direct the pre-impingement air <NUM> in discrete jets to impinge upon the interior surface <NUM> of the suction side wall <NUM>. The discrete jets of air impinge (or strike) the interior surface <NUM> (<FIG>) and create a thin boundary layer of air over the interior surface <NUM> which allows for optimal heat transfer between the suction side wall <NUM> and the air.

As used herein, the term "solid" may refer to a wall or walls that are impermeable, such that they do not allow air or other fluids to pass therethrough. For example, the first solid side <NUM> and the second solid side <NUM> may not have any impingement apertures, holes, or voids that would allow for pre-impingement air <NUM> to escape, in order to ensure all of the air gets directed towards the interior surface <NUM>, <NUM> of the walls <NUM>, <NUM> for cooling.

As shown in <FIG>, the first wall <NUM> may include a first row <NUM> of supports <NUM> that extend between first impingement side <NUM> and the first solid side <NUM>. For example, in some embodiments each support <NUM> may extend directly between the first impingement side <NUM> and the first solid side <NUM>, such that they advantageously provide additional structural integrity to the first wall <NUM>. As shown in <FIG>, each support <NUM> in the first row <NUM> of supports <NUM> may form an oblique angle <NUM> with the first solid side <NUM>, which allows the supports <NUM> to be manufactured with the first wall <NUM> via an additive manufacturing system (such as the additive manufacturing system <NUM> described herein). For example, in many embodiments, each support <NUM> in the first row <NUM> of supports <NUM> may form an oblique angle <NUM> with the first solid side wall <NUM> that is between about <NUM>° and about <NUM>°. In other embodiments, each support <NUM> in the first row <NUM> of supports <NUM> may form an oblique angle <NUM> with the first solid side wall <NUM> that is between about <NUM>° and about <NUM>°. In particular embodiments, each support <NUM> in the first row <NUM> of supports <NUM> may form an oblique angle <NUM> with the first solid side wall <NUM> that is between about <NUM>° and about <NUM>°. In many embodiments, each support <NUM> in the first row <NUM> of supports <NUM> may form an oblique angle <NUM> with the first solid side wall <NUM> that is between about <NUM>° and about <NUM>°.

Likewise, the second wall <NUM> may include a second row <NUM> of supports <NUM> that extend between second impingement side <NUM> and the second solid side <NUM>. For example, in some embodiments each support <NUM> in the second row <NUM> of supports <NUM> may extend directly between the second impingement side <NUM> and the second solid side <NUM>, such that they advantageously provide additional structural integrity to the second wall <NUM>. As shown in <FIG>, each support <NUM> in the second row <NUM> of supports <NUM> may form an oblique angle <NUM> with the second solid side <NUM>, which allows the supports <NUM> to be manufactured with the second wall <NUM> via an additive manufacturing system (such as the additive manufacturing system <NUM> described herein). For example, the in many embodiments, each support <NUM> in the second row <NUM> of supports <NUM> may form an oblique angle <NUM> with the second solid side wall <NUM> that is between about <NUM>° and about <NUM>°. In other embodiments, each support <NUM> in the second row <NUM> of supports <NUM> may form an oblique angle <NUM> with the second solid side wall <NUM> that is between about <NUM>° and about <NUM>°. In particular embodiments, each support <NUM> in the second row <NUM> of supports <NUM> may form an oblique angle <NUM> with the second solid side wall <NUM> that is between about <NUM>° and about <NUM>°. In many embodiments, each support <NUM> in the second row <NUM> of supports <NUM> may form an oblique angle <NUM> with the second solid side wall <NUM> that is between about <NUM>° and about <NUM>°.

The oblique angle <NUM>, <NUM> of the supports <NUM>, <NUM> allows the walls <NUM>, <NUM> to be additively manufactured with minimal or no defects or deformation. For example, when being additively manufactured layer by layer, such as with the additive manufacturing system <NUM> described herein, the oblique angle <NUM>, <NUM> of the supports <NUM>, <NUM> advantageously prevents the supports <NUM>, <NUM> from otherwise detrimental overhang, which could cause deformation and/or a total collapse of the component. For example, a support extending perpendicularly across the impingement may be difficult and/or impossible to manufacture using an additive manufacturing system. Thus, the oblique angle <NUM>, <NUM> between the supports <NUM>, <NUM> and solid wall <NUM>, <NUM> is favorable.

As shown in <FIG>, the first impingement side <NUM> may include a first contour that corresponds with the first wall, e.g., the pressure side wall <NUM>. Similarly, in many embodiments, the second impingement side may include a second contour that corresponds with the second wall, e.g., the suction side wall <NUM>. In this way, the impingement sides <NUM>, <NUM> may each maintain a constant spacing from the respective side walls <NUM>, <NUM> in the axial direction A, which optimizes impingement cooling thereto. As used herein, a contours that "correspond" with one another may mean two or more walls or surfaces that each have matching or generally identical curvatures in one or more directions.

In many embodiments, as shown in <FIG>, the first impingement side <NUM> may diverge away from the first solid wall <NUM> as they extend in the axial direction A. Similarly, the second impingement side <NUM> may diverge away from the second solid wall <NUM> as they extend in the axial direction A. More specifically, the first wall <NUM> may include a first parallel portion <NUM> and a first diverging portion <NUM>. The first parallel portion <NUM> of the first wall <NUM> may be disposed proximate the forward end of the cooling insert <NUM>. As shown in <FIG>, in the first parallel portion <NUM>, the first impingement side <NUM> may be generally parallel to the first solid side <NUM>. The first diverging portion <NUM> of the first wall <NUM> may extend continuously from the first parallel portion <NUM>. In the first diverging portion <NUM>, the first impingement side <NUM> may gradually diverge away from the first solid wall <NUM> as they extend in the axial direction A, such that the gap between the walls gradually increases in the axial direction A. Likewise, the second wall <NUM> may include a second parallel portion <NUM> and a second diverging portion <NUM>. The second parallel portion <NUM> of the second wall <NUM> may be disposed proximate the forward end of the cooling insert <NUM>. As shown in <FIG>, in the second parallel portion <NUM>, the second impingement side <NUM> may be generally parallel to the second solid side <NUM>. The second diverging portion <NUM> of the second wall <NUM> may extend continuously from the second parallel portion <NUM>. In many embodiments, in the second diverging portion <NUM>, the second impingement side <NUM> may gradually diverge away from the second solid wall <NUM> as they extend in the axial direction A, such that the gap between the walls gradually increases in the axial direction A.

In particular embodiments, a collection passageway <NUM> may be defined between the first solid side <NUM> and the second solid side <NUM>. For example, in many embodiments, the first solid side <NUM> and the second solid side <NUM> may be spaced apart from one another, such that the collection passageway <NUM> is defined therebetween. In many embodiments, the first solid side <NUM> and the second solid side <NUM> may each be substantially flat plates that extend parallel to one another in both the axial direction A and the radial direction R. The collection passageway <NUM> may receive low pressure air (relative to the high pressure pre-impingement air) from one or more sources and guide said low pressure air to a fuel injector <NUM>, <NUM> for usage in the secondary combustion zone <NUM>. For example, the collection passageway <NUM> may receive a first source of low pressure air from one or more of the impingement panel <NUM> collection ducts <NUM>, which is coupled to the cooling insert <NUM> via the low pressure inlet <NUM> defined within the flange <NUM>. Another source of low pressure air for the collection passageway <NUM>, as shown in <FIG>, may be post-impingement air <NUM>, which has exited the impingement sides and impinged upon the walls <NUM>, <NUM>.

As shown in <FIG> collectively, at one or more guide vanes <NUM> may extend between the first solid side <NUM> and the second solid side <NUM>, in order to guide low pressure air towards the fuel injectors <NUM>, <NUM>. In various embodiments, each guide vane <NUM> may extend directly between the first solid side <NUM> and the second solid side <NUM>, thereby coupling the first wall <NUM> of the cooling insert <NUM> to the second wall <NUM> of the cooling insert <NUM>. In particular embodiments, the guide vane <NUM> may be disposed within the collection passageway <NUM> such that low pressure air may travel along the guide vane <NUM> towards the fuel injectors <NUM>, <NUM>. In many embodiments, each of the guide vanes <NUM> may include an arcuate portion <NUM> and a straight portion <NUM> that extend continuously with one another. The arcuate portion <NUM> may be disposed proximate the forward end of the cooling insert <NUM>. The straight portion <NUM> of the guide vane <NUM> may extend from the arcuate portion <NUM> towards the aft end of the cooling insert <NUM>. In many embodiments, the straight portion <NUM> of the guide vane may be generally parallel to the axial direction A when the cooling insert is installed in an integrated combustor nozzle <NUM>.

As shown in <FIG> collectively, the first impingement side may include a first set of stand-offs <NUM> that, when the cooling insert <NUM> is installed within an integrated combustor nozzle <NUM>, extend from the first impingement side <NUM> to the first side wall (e.g. the pressure side wall <NUM>). Similarly, in many embodiments, the second impingement side includes a second set of stand-offs <NUM> that extend from the second impingement side <NUM> to the second side wall (e.g. the suction side wall <NUM>). Each set of stand-offs <NUM>, <NUM> may function to maintain adequate space between the impingement sides <NUM>, <NUM> and one of the walls <NUM>, <NUM> of the combustion liner <NUM>. For example, in exemplary embodiments, the stand-offs may extend from each respective impingement side and contact a wall <NUM>, <NUM> of the combustion liner <NUM>. For example, stand-offs are not coupled on both ends, but they are integrally formed with the impingement side <NUM>, <NUM> on one end and in contact with the interior surface of either the pressure side wall <NUM> or the suction side wall <NUM> once the cooling insert <NUM> is installed into the combustion liner <NUM>. In this way, the stand-offs <NUM>, <NUM> may be removably coupled to the combustion liner <NUM>. In exemplary embodiments, the length of the stand-offs <NUM>, <NUM> may set the distance of the gap disposed between the impingement side and the wall <NUM>, <NUM> of the combustion liner <NUM>.

<FIG> illustrates an enlarged view of two oppositely disposed cooling inserts <NUM>, in accordance with embodiments of the present disclosure. More specifically, <FIG> illustrates the closed end <NUM> of two oppositely disposed cooling inserts <NUM>. In particular embodiments, each closed end <NUM> may include an arcuate portion <NUM> that curves around the cross fire tube <NUM>. In other embodiments (not shown), in which the cross fire tube is not preset, the closed ends may extend straight across (e.g. in the axial direction A).

In many embodiments, each of the cooling inserts <NUM> may be integrally formed as a single component. That is, each of the subcomponents, e.g., the first wall <NUM>, the second wall <NUM>, the flange <NUM>, the guide vane456, the standoffs <NUM>, <NUM>, and any other subcomponent of the cooling insert <NUM>, may be manufactured together as a single body. In exemplary embodiments, this may be done by utilizing the additive manufacturing system <NUM> described herein. However, in other embodiments, other manufacturing techniques, such as casting or other suitable techniques, may be used. In this regard, utilizing additive manufacturing methods, the cooling insert <NUM> may be integrally formed as a single piece of continuous metal, and may thus include fewer sub-components and/or joints compared to prior designs. The integral formation of the cooling insert <NUM> through additive manufacturing may advantageously improve the overall assembly process. For example, the integral formation reduces the number of separate parts that must be assembled, thus reducing associated time and overall assembly costs. Additionally, existing issues with, for example, leakage, joint quality between separate parts, and overall performance may advantageously be reduced.

Claim 1:
An integrated combustor nozzle (<NUM>), including an inner liner segment (<NUM>) and an outer liner segment (<NUM>) and a combustion liner (<NUM>) that extends radially between the inner liner segment (<NUM>) and the outer liner segment (<NUM>), wherein the combustion liner (<NUM>) includes a forward end portion (<NUM>), an aft end portion (<NUM>), a first side wall (<NUM>), and a second side wall (<NUM>) wherein the aft end portion (<NUM>) of the combustion liner (<NUM>) defines a turbine nozzle, the integrated combustor nozzle (<NUM>) further including an impingement panel (<NUM>, <NUM>) disposed along an exterior surface (<NUM>, <NUM>) of one of the inner liner segment (<NUM>) or the outer liner segment (<NUM>), the impingement panel (<NUM>, <NUM>) comprising:
an impingement plate (<NUM>) for disposing along the exterior surface (<NUM>, <NUM>), wherein the impingement plate (<NUM>) defines an inner surface and an outer surface, wherein the impingement plate (<NUM>) defines a plurality of impingement apertures (<NUM>) that direct coolant in discrete jets towards the exterior surface (<NUM>, <NUM>);
a collection duct (<NUM>) spaced apart from the impingement plate (<NUM>) and defining a collection passage (<NUM>);
an inlet portion (<NUM>) including sidewalls (<NUM>) that extend from the outer surface of the impingement plate (<NUM>) to the collection duct (<NUM>), the sidewalls (<NUM>) extending axially along the impingement plate (<NUM>) and being parallel to one another such that they define an elongated slot shaped opening (<NUM>); and
at least one support (<NUM>) extending between and coupled to the impingement plate (<NUM>), a side wall of the inlet portion (<NUM>), and the collection duct (<NUM>).