Abstract: A crack-resistant vane segment assembly member for an industrial turbine engine is disclosed. The vane segment includes at least one internally-cooled body portion and inner and outer shroud portions. The body portions include end regions characterized by blending and transition zones that ensure heat is transferred at a non-crack-inducing rate from the shroud portions to the body portions. The vane segment assembly also includes a cooling arrangement that reduces the impact of thermal gradient-induced stresses acting at the interface between the body portions and shroud portions. The cooling arrangement cooperates with the transition and blending zones to produce synergistically-enhanced crack resistance properties.

Abstract: A combustor (40) for a gas turbine engine is provided with a premix pilot fuel stage (42) in order to reduce the emission of oxides of nitrogen from the engine. An in-service engine may be modified to add the premix pilot fuel stage by delivering premix pilot fuel to a ring manifold (42) for tip-feeding a premix pilot fuel outlet member such as a swirler vane (78) or fuel peg (124). In this manner, complex and expensive components such as the top hat (46), support housing (48) and diffusion pilot burner assembly (44) may be used without modification. Thermal stresses caused by the differential cooling of the ring manifold by the premix pilot fuel (96) are reduced by a heat shield (94) installed within the manifold.

Abstract: A device having an improved thermal barrier coating (46) and a process for manufacturing the same. A support structure (28) for retaining a ceramic insulating material (46) on a substrate (16) is formed by the deposition of a support structure material through a patterned masking material (14). The support structure can define cells into which the ceramic insulating material is deposited following removal of the masking material. The masking material may be patterned by known photolithographic techniques (22,24) or by laser etching (48). The support structure (28) may be a composite metal-ceramic material having either discreet layers (30,34) or a graded composition and may be deposited by an electro-desposition process followed by a heat treatment to form a solid state diffusion bond with the substrate.

Abstract: A gas turbine engine (40) having an active combustion control system (54) including a sensor element (44) positioned proximate the combustion chamber (46) as part of a sensor assembly (84) including a spring-action bellows (74). The sensor assembly is installed through an opening (69) in the casing (48) of the engine to make contact with the combustor wall (62). The bellows is compressed from its resting position by tightening mounting bolts (70) against a mounting flange (66) of the sensor assembly. The spring action of the bellows ensures contact between the sensing assembly and the combustor wall in spite of differential thermal growth between the casing and the combustor. The sensor element may be replaced by simply removing the mounting bolts without further disassembly of the engine.

Abstract: A tensioning apparatus (40) for applying a closing force across a flange assembly (42). The tensioning apparatus includes a shank member (44) and an annular member (48) connected to the shank member by an interference fit. The interference fit may be selectively relaxed by applying a fluid pressure (P1) to a groove (54) between the annular member and the shank member. A tensioner (58) is used to pre-load the shank member by pulling on the shank member while pushing on the annular member while the interference fit is sufficiently relaxed to allow relative movement between the annular member and the shank member. Once the pre-load is established, the interference fit is reestablished by releasing pressure P1 to lock the annular member in position for maintaining the closure force across the flange assembly after the tensioner is removed. A lock nut (34) may be tightened against the annular member to provide additional protection against the release of the pre-load.

Abstract: A heat tack application involves arranging an adhesive between a strand of conductive material and a strand of insulation material; applying a temperature of about 100-300° C. and a pressure of about 5-100 psi for about 5-120 seconds to tack the adhesive. A stack can thereby be formed, and a plurality of stacks assembled to form a nascent rotor coil that is subsequently arranged in a rotor slot. An applied temperature of about 100-500° C. and a pressure of about 100-1,500 psi can fully cure the adhesive after the coil is arranged within the rotor slot. Depending on the context of use, the conductive material may more generally be a first component, and the insulation material may more generally be a second component.

Abstract: A method of sealing an opening in a cast member that employs a green seal cap formed from the consolidation of a mixture of powdered metal and a binder under sufficient pressure to impart enough strength to the cap to maintain its shape during the blade manufacturing process. The green seal plate cap is inserted into the opening in the cast member and the cast member is subjected to iso-static pressing, which bonds the seal plate cap to the cast member and sinters the cap to form a solid seal.

Abstract: A method (50) of instrumenting a component (10) having a barrier coating (14). A sensor (76) is embedded within or below the coating. Material forming the sensor is deposited within a trench (80) formed into the barrier coating. The trench is then backfilled with material (70) to protect the sensor from the environment within which the component is operating. In this manner, the sensor may be embedded at any desired location and any desired depth within a barrier coating on a previously fabricated component. An array of sensors (98, 100, 102) may be embedded across the depth of the coating to provide signals indicative of operating conditions across the coating. The signals may be conducted to a connection location (24) by conductors (62, 64) that are deposited within the trench. The trench may be formed with a laser engraving process (54) and the material for the sensor and conductors may be deposited with a selective laser melting process (58).

Abstract: A method and system (100) for enhancing the determination of the presence of a surface breaking or subsurface defect with an object (114) under test are provided (FIG. 1). The method can include transferring ultrasonic energy to an object (114) under test and sensing images (514, 514?) of the object (114) under test before and after transferring ultrasonic energy to the object (114) with an infrared thermography camera (112). An increase in temperature gradients in the areas adjacent a defect (516, 516?) is shown in the images (514, 514?) produced by the camera (112), which indicates the presence of the defect (516, 516?). The temperature gradients in the area of the defect (516, 516?) and images of the defect (516, 516?) can be displayed to enable users to determine the temperature gradient and thus the extent of the defect (516, 516?). Digital images (514, 514?) of the before and after transferring ultrasonic energy can be superimposed (514?) to identify and illustrate the defect (516?).

Abstract: A brush holder (100) for carrying a brush (102) and for providing adjustment of the brush relative to the commutator (104) of a dynamoelectric machine (105). The brush holder provides for adjustment of the gap (110) between the commutator and the brush, and for adjustment of the brush in the axial direction along the commutator. The brush holder also locks the brush at the desired position for operation in the dynamoelectric machine.

Abstract: A turbine fluid guide member (10) including an airfoil portion (12), a platform portion (14) and fillet (16) joining the airfoil portion to the platform portion. Fillet cooling holes (18a-18f) are positioned in the turbine fluid guide member relative to a pressure side vortex flow (22) so that a cooling fluid flow (20) exiting the hole is directed to form a cooling film (32) over the fillet. The cooling holes may be positioned in the airfoil portion, the platform portion, or any combination thereof, depending on the geometry of the airfoil and resultant vortex flows around the airfoil. A method of cooling a fillet of the turbine fluid guide member may include identifying a vortex flow around the fillet and selectively positioning a hole relative to the vortex flow such that a cooling fluid flow exiting the hole is directed to form a cooling film over the fillet.

Abstract: A device operable in a temperature environment in excess of about 1000° C. is provided. The device comprises a substrate and a ceramic thermal barrier layer deposited on at least a portion of the substrate. The layer is formed with a ternary or pseudoternary oxide having a pyrochlore or perovskite structure and a fugative material and having pores or other voluminous defects. The thermal barrier layer advantageously is abradable.

Abstract: An assembly for mechanically clamping a laminated steel stator core including laminated steel core-end magnetic flux shunts in a dynamoelectric machine is provided. The flux shunt at each end of the stator core includes first and second surfaces for receiving the clamping assembly. The first and second surfaces may be arranged to define a step. The clamping assembly includes an inner support ring configured to engage an entire 360° circumference of the first receiving surface of the flux shunt. The clamping assembly further includes an outer support ring configured to engage an entire 360° circumference of the second receiving surface of the flux shunt. The respective mechanical engagement provided by the inner and outer rings relative to the flux shunt is circumferentially continuous.

Abstract: A system for attaching liners to a carrier for forming inner surfaces of turbine combustor. The system may include one or more liners attached to a carrier using connectors engaged to the carrier on a cold side of the liner and may include one or more liners attached to the carrier using connectors engaged to a hot side of the liners. The carrier may include one or more access ports for accessing from the hot side connectors engaged to the carrier on the cold side. In at least one embodiment, the system may include attaching all liners, except for one liner, to a carrier using connectors coupled to the carrier on the cold side and may include attaching the one liner to the carrier using connectors coupled to the carrier on the hot side.

Abstract: A method and apparatus for tuning the torsional natural frequency of a rotor is disclosed. At least one tuning slot is formed within the winding slots defined by radially projecting winding teeth. The tuning slot extends radially inward from the bottom of the winding slot a distance to tune the rotor to a desired torsional natural frequency. This tuning slot can be positioned preferably at the quadrature axis.

Abstract: A performance-enhancing fuel nozzle is disclosed. The nozzle suitable for use in combustors which combine high-swirl-number combustion in a pilot zone with low-swirl-number combustion in a main combustion zone. The nozzle includes a fuel delivery member adapted for fluid communication with a fuel source and a flow conditioning member having a fuel exit port. The fuel exit port is in fluid communication with the fuel supply and is adapted to ensure that the recirculation region adjacent the nozzle tip remains flame free. In one aspect of the invention, the fuel concentration profile of the nozzle is characterized by a radially-outward region that is flammable and a radially-inward region that is substantially non-flammable. In another aspect of the invention, the fuel exit port being is disposed a radially-outward portion of the flow conditioning member. In another aspect of the invention, the flow conditioning member is characterized by a swirl number lower than about 0.5.

Abstract: An improved turbine spring clip seal for directing gases to be mixed with fuel in a combustor basket. The turbine clip seal may include an inner housing and an outer housing. The inner housing or the outer housing, or both, may include one or more tapered leaves forming a portion of the spring clip seal. At least one leaf may include a flared end for limiting gas from passing through the slots in the spring clip seal. In at least one embodiment, the turbine clip seal may include a center sealing member positioned between the inner and outer housings.

Abstract: A turbine fluid guide member (10) including an airfoil portion (12), a platform portion (14) and fillet (16) joining the airfoil portion to the platform portion. Fillet cooling holes (18a-18f) are positioned in the turbine fluid guide member relative to a pressure side vortex flow (22) so that a cooling fluid flow (20) exiting the hole is directed to form a cooling film (32) over the fillet. The cooling holes may be positioned in the airfoil portion, the platform portion, or any combination thereof, depending on the geometry of the airfoil and resultant vortex flows around the airfoil. A method of cooling a fillet of the turbine fluid guide member may include identifying a vortex flow around the fillet and selectively positioning a hole relative to the vortex flow such that a cooling fluid flow exiting the hole is directed to form a cooling film over the fillet.

Abstract: A gas turbine engine (10) includes a catalytic oxidation module (28). The catalytic oxidation module includes a pressure boundary element (30); a catalytic surface (32); and an opening (34) in the pressure boundary element to allow premixing of the fluids before the fluids enter a downstream plenum. In an embodiment, the pressure boundary element includes a catalyst-coated tube (58) having holes (68) formed therein to allow mixing across the tube. In another embodiment, the pressure boundary element includes a tubesheet (44) having a first fluid passageway intersecting a second fluid passageway to premix the fluids upstream of the outlet end of the tubesheet. In yet another embodiment, the catalytic oxidation module includes an upstream tubesheet (86) for mounting a tube inlet end (73) and a downstream tubesheet (78) for mounting a tube outlet end (72) so that the tube is slidably contained there between.

Abstract: A exemplary method of depositing a coating on a substrate using a spray process is provided that may include selecting a desired dominant feature (62) for the coating and controlling the spray process (64, 68) to have at least one of an in-flight particle temperature distribution and an in-flight particle velocity distribution predicted to produce the dominant feature. One aspect allows for adjusting (64, 68) the at least one distribution to cause the distribution to shift from an in-flight Gaussian particle distribution to an in-flight non-Gaussian particle distribution. It may be determined whether the dominant feature for the coating is deposited within acceptable limits (66) and adjusting the at least one in-flight particle distribution (68) if the dominant feature for the coating is not deposited within acceptable limits. One aspect allows for depositing on the substrate a spray jet of particles having a bimodal distribution of particle temperature and a bimodal distribution of particle velocity.