Conformal and flexible woven heat shields for gas turbine engine components

A method of forming a heat shield for a rigid component of a combustor section of a gas turbine engine comprising

• the rigid component is a fuel structure of a combustor of the combustor section of the gas turbine engine, wherein the fuel structure is configured to deliver fuel to the combustor;
• and
• the method further comprising:
• additively manufacturing the fuel structure;
• and
• additively manufacturing a woven heat shield around the fuel structure, wherein the woven heat shield at least partially conformally surrounds the fuel structure and is spaced from an exterior of the fuel structure by a distance where the woven heat shield conformally surrounds the fuel structure, the woven heat shield comprising:
• a first set of strands, wherein each strand of the first set of strands extends in a first direction;
• a second set of strands interwoven with the first set of strands, wherein each strand of the second set of strands extends in a second direction transverse to the first direction;
• and
• a weave pattern comprising the first set of strands and the second set of strands, wherein the first set of strands and the second set of strands are not attached where they intersect in the weave pattern, such that the first set of strands are able to move relative to the second set of strands when undergoing thermal expansion;
• wherein:
• each strand of the first set of strands and the second set of strands does not contact any other strand of the first set of strands and the second set of strands at an ambient temperature;
• the woven heat shield defines an air gap that extends between an inner surface of the woven heat shield and an outer surface of the fuel structure;
• and
• the woven heat shield is configured to trap an insulating layer of stagnant air against the outer surface of the fuel structure.

A method of forming a heat shield for a rigid component of a combustor section of a gas turbine engine comprising

• the rigid component is a fuel structure of a combustor of the combustor section of the gas turbine engine, wherein the fuel structure is configured to deliver fuel to the combustor;
• and
• the method further comprising:
• additively manufacturing a woven heat shield, wherein the woven heat shield is at least partially annular and the annular portion has a larger diameter than a dimension of the fuel structure;
• the woven heat shield comprising:
• a first set of strands, wherein each strand of the first set of strands extends in a first direction;
• a second set of strands interwoven with the first set of strands, wherein each strand of the second set of strands extends in a second direction transverse to the first direction;
• and
• a weave pattern comprising the first set of strands and the second set of strands;
• placing the fuel structure within the annular portion of the woven heat shield;
• and
• mechanically tightening the weave pattern of the woven heat shield after placing the fuel structure within the annular portion to create a conformal fit of the woven heat shield about the fuel structure, wherein the woven heat shield at least partially conformally surrounds the fuel structure and is spaced from an exterior of the fuel structure by a distance where the woven heat shield conformally surrounds the fuel structure, wherein the first set of strands and the second set of strands are not attached where they intersect in the weave pattern, such that the first set of strands are able to move relative to the second set of strands when undergoing thermal expansion;
• wherein:
• each strand of the first set of strands and the second set of strands does not contact any other strand of the first set of strands and the second set of strands at an ambient temperature;
• the woven heat shield defines an air gap that extends between an inner surface of the woven heat shield and an outer surface of the fuel structure;
• and
• the woven heat shield weave pattern is configured to trap an insulating layer of stagnant air against the outer surface of the fuel structure.