Abstract: An electric discharge machining (EDM) device includes a circular blade, a motor coupled to the circular blade for rotating the circular blade, and an electric discharge control system operatively coupled to the circular blade and a workpiece. The electric discharge control system causes the rotating circular blade to cut the workpiece using electric discharge machining. The device allows for removal of large chunks of material using EDM, minimizing the number of cuts, time and energy required to create a part.

Abstract: A method of assembling a turbomachine that includes a rotor and a stationary component is provided. The method includes coupling a housing to the stationary component using at least one biasing member, wherein the housing extending circumferentially about the rotor. The method also includes coupling at least one annular ring to the housing, and coupling a plurality of plate members to the housing such that the at least one annular ring extends from the housing towards the rotor and partially through the plurality of plate members.

Abstract: A turbomachine seal assembly includes a plurality of sealing strips configured and disposed to inhibit a flow of fluid from passing through a channel defined by a first member and a second member. At least one of the plurality of sealing strips includes a paddle element that is configured and disposed to create a fluid recirculation zone at the channel. The fluid recirculation zone further inhibits the flow of fluid through the channel.

Abstract: A brush seal and brush seal segment for use in a rotary device are provided. In one embodiment, the invention provides a brush seal comprising: a plurality of brush seal segments, each segment including: an arcuate fence; an arcuate backplate substantially circumferentially coextensive with the arcuate fence, the arcuate backplate including a first end and a second end; and a plurality of brush seal bristles between the arcuate backplate and the arcuate fence, the plurality of brush seal bristles being angled with respect to a radial axis of the arcuate backplate and at least one of the first end and the second end of the arcuate backplate; and a static member to which at least one of the plurality of brush seal segments is affixed.

Abstract: A seal assembly for a turbomachine includes a plurality of compliant plate members attached to an interior surface of a stationary housing. The compliant plate members define a sealing ring between the stationary housing and a rotor. Each of the compliant plate members comprises at least one slot therein. The seal assembly further includes at least one arcuate static ring attached to the interior surface of the stationary housing and extending radially into the at least one slot in the compliant plate members. Each of the at least one static ring extends circumferentially through and between a plurality of the compliant plate members. Finally, the seal assembly includes a vibration damper disposed adjacent to or provided on the plurality of compliant plate members. The vibration damper is configured to dampen vibration of the plurality of compliant plate members.

Abstract: Conventional electrochemical machining process requires fixed shaped tool cathodes, which makes retooling time consuming and expensive. Flexible tool cathodes include elastically deformable cathodes that can deform in two or three dimensions and can adapt to the contour of the workpiece while the workpiece is moving relative to the flexible tool cathode. That is, the flexible tool cathode can perform tracing. Certain flexible tool cathodes can be also used for special configurations such corners and edges. The flexible tool cathodes can be used to polish, finish, or shape the workpiece through electrochemical processes.

Abstract: A method of manufacturing a brush seal includes the steps of maintaining a pair of first elongated frames spaced from one another on a fixture; wrapping wire strands about and longitudinally along the pair of frames in multiple longitudinal wire passes forming wire runs; disposing two pairs of first elongated plates between the wire runs at respective locations spaced from one another along the wire runs and at an angle to the wrapped strands with the plates of each of two pairs lying parallel to and in registration with one another; clamping two pairs of second elongated plates at second respective locations along an outside of the wire runs with each pair of the second plates registering with each pair of the first plates, the two pairs of second plates extending generally parallel to the pairs of the first plates; cutting the wrapped strands outside of and beyond the first and second pairs of plates forming two wire strand runs with both ends of each of the runs disposed between and straddled by the first

Abstract: According to various embodiment, a system includes an electrolytic cutting tool. The electrolytic cutting tool includes a first cathode configured to be positioned at a first gap away from a first side of a workpiece, a second cathode configured to be positioned at a second gap away from a second side of the workpiece. The first and second cathodes are positioned opposite from one another. The electrolytic cutting tool also includes a first electrolyte passage configured to flow a first electrolyte through the first gap between the first cathode and the workpiece, a second electrolyte passage configured to flow a second electrolyte through the second gap between the second cathode and the workpiece, and a power supply configured to flow current through the first gap and the second gap to cause electrolytic dissolution through the workpiece from both the first side and the second side.

Abstract: A method for fabricating a brush seal assembly comprising, bending a first plate member to a helical shape, bending a second plate member to a helical shape, securing the first plate member to a drum, winding a wire material around the drum and the first plate member, securing the second plate member to the drum, attaching the second plate member and the first plate member to the wire, and cutting the wire to define a bristle length.

Abstract: A method for fabricating a brush seal assembly comprising, bending a first plate member to a helical shape, bending a second plate member to a helical shape, securing the first plate member to a drum, winding a wire material around the drum and the first plate member, securing the second plate member to the drum, attaching the second plate member and the first plate member to the wire, and cutting the wire to define a bristle length.

Abstract: A brush seal, brush seal segment, and brush seal backplate for use in a rotary device are provided. In one embodiment, the invention provides a brush seal for a rotary device, the brush seal comprising: a plurality of brush seal segments, each segment including: an arcuate fence; an arcuate backplate circumferentially coextensive with the arcuate fence, the arcuate backplate including: a plurality of circumferentially-oriented cavities; a first dam along a first end of the arcuate backplate, the first dam substantially closing an end of at least one of the plurality of circumferentially-oriented cavities; and a second dam along a second end of the arcuate backplate, the second dam substantially closing an end of at least one of the plurality of circumferentially-oriented cavities; a plurality of brush bristles between the arcuate backplate and the arcuate fence; and a static member to which at least one of the plurality of brush seal segments is affixed.

Abstract: A method and seal assembly for a rotary machine including a rotary component and a stationary component is provided. The method includes providing a seal housing including a front plate and a back plate that is spaced from the front plate such that a cavity is defined between the front plate and the back plate. The method also includes coupling a plurality of flexible compliant plates to at least one of the seal housing and the stationary component such that the compliant plates are spaced from the front plate and the back plate within the cavity, and coupling at least one projection to at least one of the seal housing and the compliant plates such that the at least one projection facilitates reducing flow through at least one of a first axial gap and a second axial gap that are defined between the seal housing and the compliant plates.

Abstract: An electric discharge machining (EDM) device includes a circular blade, a motor coupled to the circular blade for rotating the circular blade, and an electric discharge control system operatively coupled to the circular blade and a workpiece. The electric discharge control system causes the rotating circular blade to cut the workpiece using electric discharge machining. The device allows for removal of large chunks of material using EDM, minimizing the number of cuts, time and energy required to create a part.

Abstract: A compliant plate seal arrangement manufacturing method is provided. A compliant plate seal manufacturing method includes assembling a plurality of t-shims and a plurality of spacer shims into a straight weld fixture, thereby forming a shim pack having a front and rear end and sides, welding the sides of the shim pack to a top plate, removing a portion of the weld fixture, removing the plurality of spacer shims, shaping the shim pack into a target diameter, and applying a radial flow plate to the leaf pack.

Abstract: A method for fabricating a brush seal assembly comprising, bending a first plate member to a helical shape, bending a second plate member to a helical shape, securing the first plate member to a drum, winding a wire material around the drum and the first plate member, securing the second plate member to the drum, attaching the second plate member and the first plate member to the wire, and cutting the wire to define a bristle length.

Abstract: A compliant plate seal manufacturing method is provided. The method includes assembling a plurality of compliant plates and a plurality of spacer shims into a weld fixture, thereby forming a leaf pack having a front and rear end and sides and a curvature, welding the sides of the leaf pack to hook plates on the weld fixture, removing a portion of the weld fixture, removing a portion of the hook plates and applying a radial flow plate to the leaf pack.

Abstract: A bling nozzle/carrier interface design for a steam turbine is provided wherein there is limited contact between the carrier (casing, shell) to allow for ease of assembly. There is also limited contact in strategic locations to both reduce the roll, or downstream deflection, of the inner portion and to improve disassembly due to limited contact in areas where corrosion can occur.

Abstract: A packing ring assembly is provided and includes an arcuate carrier ring segment, an arcuate packing ring segment movable relative to the carrier ring segment, an attachment component disposed in association with the packing ring segment and in association with the carrier ring segment, and an actuator component configured to maintain the packing ring segment in a first position and to allow a movement of the packing ring segment to a second position when the packing ring assembly is exposed to a pressure condition.

Abstract: A shaft seal reduces leakage between a rotating shaft such as a rotor and a stator. The shaft seal or shingle seal includes a plurality of compliant-plate members attached to the stator in facing relation. The compliant-plate members define a sealing ring between the stator and the rotating shaft. Each of the compliant-plate members includes a plurality of shingles, where adjacent compliant-plate members are disposed relative to each other such that the shingles are at least partially staggered in a direction of axial leakage.

Abstract: A method of manufacturing a brush seal includes the steps of maintaining a pair of first elongated frames spaced from one another on a fixture; wrapping wire strands about and longitudinally along the pair of frames in multiple longitudinal wire passes forming wire runs; disposing two pairs of first elongated plates between the wire runs at respective locations spaced from one another along the wire runs and at an angle to the wrapped strands with the plates of each pair lying parallel to and in registration with one another; clamping two pairs of second elongated plates at respective locations along an outside of the wire runs with each pair of second plates registering with the respective first pairs of plates, the two pairs of second plates extending generally parallel to the pairs of the first plates; cutting the wrapped strands outside of and beyond the first and second pairs of plates forming two wire strand runs with both ends of each run disposed between and straddled by a pair of plates; welding the