Solar Turbines Inc.

Bruce D Harkins

Charles W Bucey

Michael E Ward

Michael S Nowak

Doug R Ervin

Jan Illakowicz

Tod Papai

A method of attaching an air duct to a recuperator core may include welding a pair of butterpasses along a length of each of a plurality of core portions, connecting the plurality of core portions to one another to form the recuperator core and a pair of butterpasses extending along a length of the recuperator core, and attaching the air duct to the recuperator core along at least a portion of the pair of butterpasses. The method may also include controllably moving a welding torch into the air duct and along substantially the length of the recuperator core and controllably welding each butterpass to the air duct along substantially the length of the recuperator core without adding metal to the weld.

Method for attaching an air duct to a recuperator core

An apparatus for manufacturing a cell of a recuperator wherein the cell includes a plurality of primary surface sheets, a plurality of spacer bars and a pair of guide vanes. A fixture has a top portion and a bottom portion. The top portion is pivotably movable between an open or loading position and a closed or welding position. A plurality of the spacer bars, plurality of primary surface sheets and a pair of guide vanes are positioned in the fixture in a preestablished relationship and are fixedly attached one to another by a tack welding machine. A controller operative controls the tack welding machine.

Apparatus for tack welding a recuperator cell

A cell of a recuperator has a passage therein having a first end and a second end. In use a fluid passes through the passage under pressure. The cell must be tested to determine an operational efficiency or leakage within the passage. A pair of sealing mechanisms is positioned at a respective one of the first end and the second end of the passage. A vacuum is pulled across the passage and a rate of leakage is monitored to define an operational cell and a failed cell.

Apparatus and method for testing a recuperator cell for an air leak

Recuperators include a core which is commonly constructed of a plurality of relatively thin flat sheets having an angled or corrugated spacer fixedly attached therebetween. The sheets are joined into cells, sealed and form passages between the sheets. These cells are stacked or rolled and form alternate air (recipient) cells and hot exhaust (donor) cells. Compressed discharged air from a compressor of the engine passes through the air cell while hot exhaust gas flows through alternate cells. The exhaust gas heats the sheets and the spacers, and the compressor discharged air is heated by conduction from the sheets and spacers. The need for repeatability of construction of each cell assures that the final recuperator is economically and easily assembled. Examples, of such repeatability required includes length, height, thickness, weld size, weld position, weld splatter and others. The recuperator assembly method provides a cell and a recuperator having repeatability of length, height, thickness, weld size, weld position, weld splatter and others.

Recuperator cell assembly system

Many recuperators have components which react to corrosive gases and are used in applications where the donor fluid includes highly corrosive gases. These recuperators have suffered reduced life, increased service or maintenance, and resulted in increased cost. The present header assembly when used with recuperators reduces the brittle effect of a portion of the ceramic components. Thus, the present header assembly used with the present recuperator increases the life, reduces the service and maintenance, and reduces the increased cost associated with corrosive action of components used to manufacture recuperators. The present header assembly is comprised of a first ceramic member, a second ceramic member, a reinforcing member being in spaced relationship to the first ceramic member and the second ceramic member. The header assembly is further comprised of a refractory material disposed in contacting relationship with the first ceramic member, the second ceramic member and the reinforcing member and having a strengthening member wrapped around the refractory material. The present header assembly provides a high strength load bearing header assembly having good thermal cycling characteristics, good resistance to a corrosive environment and good steady state strength at elevated temperatures.

High pressure ceramic heat exchanger

Many recuperators have components which react to corrosive gases and are used in applications where the donor fluid includes highly corrosive gases. These recuperators have suffered reduced life, increased service or maintenance, and resulted in increased cost. The present header assembly when used with recuperators reduces the brittle effect of a portion of the ceramic components. Thus, the present header assembly used with the present recuperator increases the life, reduces the service and maintenance, and reduces the increased cost associated with corrosive action of components used to manufacture recuperators. The present header assembly is comprised of a first ceramic member, a second ceramic member, a strengthening reinforcing member being in spaced relationship to the first ceramic member and the second ceramic member. The header assembly is further comprised of a refractory material disposed in contacting relationship with the first ceramic member, the second ceramic member and the strengthening reinforcing member. The present header assembly provides a high strength load bearing header assembly having good thermal cycling characteristics, good resistance to a corrosive environment and good steady state strength at elevated temperatures.

Many recuperators have components which react to corrosive gases and are used in applications where the donor fluid includes highly corrosive gases. These recuperators have suffered reduced life, increased service or maintenance, and resulted in increased cost. The present joint when used with recuperators increases the use of ceramic components which do not react to highly corrosive gases. Thus, the present joint used with the present recuperator increases the life, reduces the service and maintenance, and reduces the increased cost associated with corrosive action of components used to manufacture recuperators. The present joint is comprised of a first ceramic member, a second ceramic member, a mechanical locking device having a groove defined in one of the first ceramic member and the second ceramic member. The joint and the mechanical locking device is further comprised of a refractory material disposed in the groove and contacting the first ceramic member and the second ceramic member. The present joint mechanically provides a high strength load bearing joint having good thermal cycling characteristics, good resistance to a corrosive environment and good steady state strength at elevated temperatures.

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San Diego, CA, United States of America

Bruce D Harkins