Fuel Nozzle Swirl Plates

Fuel nozzle swirl plates are designed with controlled vane angles and passage configurations that impart angular momentum to the fuel-air mixture, creating a stable recirculation zone downstream of the nozzle exit. The geometry promotes effective mixing at the droplet level by enhancing turbulence intensity in a confined volume, resulting in a highly homogeneous fuel-air mixture prior to ignition. This improves flame stability and ensures consistent combustion, especially in engines operating with lean equivalence ratios or variable load conditions. 

Fuel nozzle swirl plates operate under extreme conditions where thermal gradients exceed 200°C/mm and surface temperatures approach 1100–1300°C. To counteract such stresses, plates are manufactured from wrought or cast nickel-based superalloys such as Inconel 718 or Hastelloy X. These alloys exhibit superior creep strength, oxidation resistance, and thermal fatigue endurance. Grain structure control and post-machining heat treatment processes are applied to maintain dimensional integrity under cyclic heating and cooling, reducing the risk of vane warping or cracking during engine operation.