Abstract: A method is provided that facilitates additive manufacturing a superalloy component using a liquid assisted additive manufacturing process. The method includes successively depositing and fusing together layers of a superalloy powder mixture comprising a high melt superalloy powder and a low melt superalloy powder to build up an additive portion of the superalloy component. The method may further include heat treating the additive portion to form a homogenized base alloy of which the additive portion is comprised, which base alloy has a chemistry defined by the superalloy powder mixture. Each of the high melt superalloy powder, the low melt superalloy powder, and the superalloy powder mixture may have a nickel content by weight greater than 40% and have an aluminum content by weight of greater than 1.5%.

Abstract: Systems (100) and methods (1000) for additively manufacturing or repairing a component from a base material (10). The system may include a laser metal deposition (LMD) system (200) operably connected to a means for cooling (300) the base material during laser processing of additive materials deposited in a melt pool on the base material. The LMD system includes a laser energy source (202) configured to direct laser energy towards the base material to form the melt pool thereon and to processes the deposited additive materials to form layers on the base material upon solidification. The means for cooling may be configured to cool the base material to within a cooling temperature range during the LMD process, which results in, e.g., a cooling/freezing effect. This cooling effect shortens the solidification period during laser processing and allows for weld heat to be released from the base material.

Abstract: A generator supported by a foundation includes a generator housing defining a first side and a second side that extend along a rotational axis of the generator, a first frame foot removably attached to the first side, and a second frame foot removably attached to the second side, wherein a height of the first frame foot and the second frame foot is selected to position the rotational axis at a desired height above the foundation, and wherein a width of the first frame foot and the second frame foot is selected to engage the foundation.

Abstract: A turbine assembly includes a rotating blade including a T-root. The T-root defines a first engagement surface that is cylindrical, a rotor including a blade groove arranged to receive the rotating blade, the blade groove including a neck portion that defines a second engagement surface and a neck surface that is normal to and intersects the second engagement surface. The second engagement surface is cylindrical, and a relief groove is formed in the neck surface and positioned adjacent the second engagement surface.

Abstract: A floating master controller system is provided that includes a plurality of hardware units, each capable of carrying out at least one mechanical function. Each hardware unit includes a processor configured via controller code included in a memory to cause the respective hardware unit to operate and carry out the at least one mechanical function. The controller code for each hardware unit includes a master controller (MC) application and at least one floating master controller (FMC) application. Each MC application is operably configured to function as an active master controller that controls the at least one mechanical function in each of the plurality of hardware units in the system and is operably configured to control the at least one mechanical function for its respective hardware unit responsive to tracking another one of the MC applications that is functioning as the active master controller in the system.

Abstract: A system for manufacturing of a sintered wire and in-situ feeding to a laser wire welding system is presented. The system includes a pressure vessel connected to a powder feed system for delivering at least two powders to a powder mixing zone of the pressure vessel. The at least two powders are mixed via a rotating cone in the pressure vessel. After mixing, a heating device contained within the pressure vessel heats the mixture so that liquid phase sintering occurs and a sintered rod is created. The sintered wire is continuously fed to a laser metal deposition system for depositing a layer of additive material on a base material. A method of additively manufacturing or repairing a superalloy component is also presented.

Abstract: A method of forming a component includes mixing a powdered base material and a binder to define a mixture, forming the mixture into a desired shape without melting the base material, removing the binder from the desired shape to define a skeleton, the volume of the skeleton being between 80 percent and 95 percent base material, and infiltrating the skeleton with a melting point depressant material to define a finished component, the finished component having less than one percent porosity by volume.

Abstract: A method for repairing a tip portion of a turbine component having a structural defect is provided. The method includes removing a damaged section in turbine component with a structural defect in a tip portion of the turbine component. A pre-sintered preform is provided including a first portion having a first composition and a second portion having a second composition. The pre-sintered preform is configured to mate with an upper surface of a remaining portion of the turbine component. The method also includes applying the pre-sintered preform to the upper surface, wherein the PSP comprises a superalloy material and a braze material. The PSP and the remaining portion of the turbine component are subjected to a brazing process to melt the braze material and fill in the structural defect.

Abstract: A blade for a gas turbine includes a removed portion space, and further includes an airfoil portion defining the removed portion space, the airfoil portion formed from a base material, and a replacement component formed to fill the removed portion space. The replacement component is formed from a material that includes 50%-80% base material, 0%-30% braze material, and 0%-8% aluminum. A braze joint is formed between the airfoil portion and the replacement component to attach the replacement component to the airfoil portion and fill the removed portion space.

Abstract: A power plant is operable to provide primary frequency control for a grid. The power plant includes a gas turbine operable to power a first generator that is synchronized to the power grid and to produce an exhaust gas, the gas turbine operated at a power level that defines a non-zero first MW margin and including a first control system having a first droop setting, and a heat recovery steam generator (HRSG) operable to generate high pressure steam in response to the passage of the exhaust gas through the HRSG. A steam turbine is operable to power a second generator that is synchronized to the power grid, the steam turbine is operated at a power level that defines a non-zero second MW margin and includes a second control system having a second droop setting, the second droop setting set to a value based at least in part on the second MW margin.

Abstract: A valve assembly for a reciprocating gas compressor includes a seat, a guard plate attached to the seat, elements, and springs is presented. The seat defines inlet openings, each inlet opening extends through the seat along a central longitudinal axis of each inlet opening. The guard plate defines element bores, each element bore aligning with one of the inlet openings along the central longitudinal axis. Each element includes a first end with a first recessed surface and a second end with a second recessed surface, the first end and the second end cooperating to define a cylindrical shape therebetween, and an extension protruding outward from the outer diameter of the element. Each element is positioned within one of the element bores and movable between an open position in which the element contacts the guard plate and a closed position in which the element contacts the seat.

Abstract: A bearing and/or seal assembly where pressurized gas (e.g., air) may be arranged to produce a contact-free bearing and/or seal is provided. The assembly includes a permeable body (12) including structural features (13) selectively engineered to convey a pressurized gas (Ps) from an inlet side (20) side of the permeable body to an outlet side (22) of the permeable body to form an annular film of the pressurized gas relative to the rotatable shaft. Disclosed embodiments may be produced by way of three-dimensional (3D) Printing/Additive Manufacturing (AM) technologies with practically no manufacturing variability; and may also cost-effectively and reliably benefit from the relatively complex geometries and the features and/or conduits that may be involved to, for example, form the desired distribution pattern or impart a desired directionality to the pressurized gas conveyed through the permeable body of the bearing and/or seal assembly.

Abstract: A gas turbine sealing interface to seal a gap between a transition duct and a turbine section component is provided. The transition duct includes an outlet exit frame including at least one fastener hole. The turbine section component includes a first stage vane structure including an upstream lip. A seal couples the outlet exit frame to the first stage turbine vane structure. An L-shaped rail including a flat portion and a lipped portion disposed perpendicularly to the flat portion. The seal is secured to the outlet exit frame via the L-shaped rail. An upstream portion of the seal includes a U-shaped cross section forming a first groove. A downstream portion of the seal comprises a groove which engages the upstream lip of the first stage turbine vane structure. A gas turbine engine including a radially inner sealing interface and a radially outer sealing interface is also provided.

Abstract: A method of cleaning a component includes providing the component following the operation of the component in a high temperature environment, the component including a thermal barrier coating (TBC), cleaning the TBC of the component using a sponge jet blasting process, and measuring a cleaned thickness of the TBC to verify that the cleaned thickness exceeds a predetermined minimum value that will allow the return of the component to the high temperature environment.

Abstract: Non-destructive inspection systems (10) and methods for inspecting structural flaws that may be in a structure (15) based on guided wave thermography. The method may include sweeping a frequency-phase space to maximize ultrasonic energy distribution across the structure while minimizing input energy, e.g., via a plurality of actuators. The system may include transducer elements (12, 14, 16, 17) configured to predominantly generate shear horizontal-type guided waves in the structure to maximize thermal response from any flaws.

Abstract: A generator air gap baffle train assembly includes linearly aligned baffle segments, linearly aligned wedge blocks, and a tensioning rod. Each baffle segment includes a radially outer portion having an outer surface to interface with the axial slot and a side surface angled with respect to the outer surface and an axially aligned first thru bore and a radially inner portion which projects into an air gap. A pair of wedge blocks are positioned on opposing sides of the radially outer portion, each wedge block including a side surface that interfaces with the side surface of the radially outer portion so that the interfacing surfaces are in abutting contact and an outer surface that interfaces with the axial slot and a second thru bore axially aligned with the first thru bore of each baffle segment. The tensioning rod is enclosed by a non-conducting hollow tube spanning between adjacent baffle segments.

Abstract: A power plant is provided including a heat recovery steam generator positioned to receive a flow of an exhaust gas and having a heating surface, an exhaust gas recirculation line branching off at an extraction point within the heat recovery steam generator and opening into the heat recovery steam generator at an injection point upstream of the extraction point within the heat recovery steam generator, a thermal storage system arranged between the extraction point and the injection point in the exhaust gas recirculation line wherein the thermal energy storage system stores thermal energy, and a blower arranged in the exhaust gas recirculation line to push air or exhaust gas through the thermal energy storage system.

Abstract: A locking wedge system for securing a stator coil in a slot of a stator core includes a slot layer positioned on the stator coil to inhibit movement of the stator coil within the slot, an outer wedge including a first tapered surface, an inner locking wedge positioned on the slot layer, the inner locking wedge including a second tapered face that interfaces with the first tapered face, a locking member configured to lock the inner locking wedge to the stator core, and an interlocking mechanism to couple the outer wedge to the inner locking wedge.

Abstract: A device to extract a support yoke from a reheat stop valve of a steam turbine is provided. The device includes a hydraulic cylinder for applying a pushing force to the support yoke, an attachment weldment for attaching the hydraulic cylinder to the reheat stop valve casing, and a conical cylinder coupled to the hydraulic cylinder and configured to evenly impart the pushing force to the support yoke from within the reheat stop valve in order to separate the reheat stop valve from the support yoke. A method to extract a support yoke from a reheat stop valve of a steam turbine is also provided.