This work involves the exploration of design and prototyping of a Dry Low-NO_x (DLN) fuel injector with integrated temperature sensing capabilities using the electron beam melting (EBM) additive manufacturing (AM) process. Low-NO_x natural gas fuel injectors, commonly used in Dry Low NO_x (DLN) gas turbine combustors, have complex internal cavities and passages to ensure tailored mixing of air and fuel to achieve ultra-low levels of NO_x emissions. Since the current design methodology of these injectors is based on conventional fabrication techniques (e.g., multi-step machining and welding processes), a new paradigm of design methodology needs to be developed for their adaptation to the EBM fabrication process.

The proposed effort has three specific objectives: (1) development of design methodologies for Low-NO_x fuel injectors with embedded temperature capabilities for EBM based 3D Manufacturing; (2) development of optimum EBM process parameters and powder removal techniques to remove sintered powder from internal cavities and channels of Low-NO_x fuel injectors with embedded temperature sensors; and (3) testing of the EBM fabricated Low-NO_x fuel injector with integrated temperature measurement capabilities in a High Pressure Laboratory turbine combustor.