Siemens Energy, Inc.

Siemens Aktiengesellschaft

David G Sansom

Ching-Pang Lee

Gm Salam Azad

Neil Hitchman

Kok-Mun Tham

Zhihong Gao

Ramesh Subramanian

Nicholas F Martin, Jr

Barrry L Allmon

Gerald Joseph Bruck

Gary Brian Merrill

Vincent Paul Laurello

David B Allen

Cora Schillig

Jonathan E Shipper

Dimitrios Zois

Anirudha Vaidya

Metallic components, including superalloy components such as turbine vanes and blades, are joined or repaired by electric resistance with a high electrical resistivity brazing alloy composition. In some embodiments the brazing alloy comprises filler metal selected from the group consisting of nickel, iron, and cobalt base alloy and elements selected from the group consisting of phosphorous (P), boron (B), silicon (Si), germanium (Ge), sulfur (S), selenium (Se), carbon (C), tellurium (Te) and manganese (Mn). In performing the method of the present invention a high electrical resistivity brazing alloy composition is introduced within a substrate defect or interposed between two substrates that are to be joined. An electric current is passed through the brazing alloy until the alloy melts and bonds to the adjoining substrate. High resistivity of the brazing alloy concentrates heat generated by the current flow in the brazing alloy rather than in the substrate.

Method for resistance braze repair

Turbine and compressor casing abradable component embodiments for turbine engines, with composite grooves and vertically projecting asymmetric non-parallel walls or trapezoidal cross section ridges that reduce, redirect and/or block blade tip airflow leakage downstream into the grooves rather than from turbine blade airfoil high to low pressure sides. In some embodiments at least one angularly oriented first groove formed in the ridge plateau is adapted for angular orientation upstream a turbine blade rotation direction to resist blade tip airflow leakage and the ridges are separated by second grooves that are skewed relative to the respective ridge plateaus and the substrate that are also adapted for orientation upstream the turbine blade rotation direction to resist blade tip airflow leakage.

Turbine abradable layer with asymmetric ridges or grooves

Turbine and compressor casing abradable component embodiments for turbine engines, with composite grooves and vertically projecting alternating rows of first and second height ridges in planform patterns, to reduce, redirect and/or block blade tip airflow leakage downstream into the grooves rather than from turbine blade airfoil high to low pressure sides. The first ridges have a first ridge height greater than that of the second ridges. These ridge or rib embodiments have first lower and second upper wear zones. The lower zone, at and below the second ridge height, optimizes engine airflow characteristics, while the upper zone, between tips of the second and first ridges, is optimized to minimize blade tip gap and wear by being more easily abradable than the lower zone.

Turbine abradable layer with progressive wear zone multi level ridge arrays

Turbine and compressor casing abradable component embodiments for turbine engines, with composite grooves and vertically projecting rows of ridges in planform patterns, establishing upper and lower wear zones. The lower wear zone reduces, redirects and/or blocks blade tip downstream airflow leakage, while the upper wear zone is optimized to minimize blade tip gap and wear by being more easily abradable than the lower zone. An elongated first ridge in the lower wear zone terminates in a continuous surface plateau. A plurality of second ridges or nibs, separated by grooves, project from the plateau, forming the upper wear zone. Each of the second ridges has a planform cross section smaller than the plateau planform cross section and a height smaller than the first ridge height. Some embodiments of the second ridges have spacing, planform cross sections, heights and separating groove dimensions selected for shearing when contacted by turbine blade tips.

Turbine abradable layer with progressive wear zone having a frangible or pixelated nib surface

Turbine and compressor casing abradable component embodiments for turbine engines, with composite grooves and vertically projecting rows of stepped first ridges in planform patterns, to reduce, redirect and/or block blade tip airflow leakage downstream into the grooves rather than from turbine blade airfoil high to low pressure sides. Each stepped first ridge has a first portion proximal the substrate surface with a pair of first opposed lateral walls terminating in a plateau, and a second portion terminating in a ridge tip. These ridge or rib embodiments have first lower and second upper wear zones. The lower zone, which at and below first portion height, optimizes engine airflow characteristics, while the upper zone, between the plateau and the second portion ridge is optimized to minimize blade tip gap and wear by being more easily abradable than the lower zone.

Turbine abradable layer with progressive wear zone terraced ridges

A compliant, impact-absorbing layer () on a thermal barrier coating (TBC) () on a substrate (). The impact-absorbing layer () has an internal structure of planar grains () oriented parallel to the substrate so the impact-absorbing layer preferentially fractures horizontally and it blocks vertical cracking. A ceramic armor layer () on the impact-absorbing layer has a higher density, and is fractured () into fracture plates () of a designed size. This provides a thermal barrier with particle impact-resistance that may be applied to gas turbine components where needed.

Damage resistant thermal barrier coating and method

A method of measuring a thickness of a coating on a substrate material. A first pulse of monochromatic light having a predetermined first wavelength is emitted toward the coating and substrate material. A second pulse of monochromatic light having a predetermined second wavelength is emitted toward the coating and substrate material, the second wavelength being different than the first wavelength. A first elapsed time is measured from emission of the first pulse of light to reception of a reflection of the first pulse of light from a surface of the substrate material at an interface with the coating. A second elapsed time is measured from emission of the second pulse of light to reception of a reflection of the second pulse of light from an outer surface of the coating. A thickness of the coating is determined as a function of a difference between the first and second elapsed times.

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Lake Wyle, SC, United States of America

David G Sansom