Abstract: A method is provided for restoring a near-wall channeled gas turbine engine component (100, 200) which has been exposed to engine operation. In a representative embodiment, a cooling channel (102) of the component (100) is filled with a polymer that solidifies to form a preform material (110) in the cooling channel (102). Then existing outer wall layers (106, 108) of the component (100) are removed, thereby exposing in part the preform material (110). New outer wall layers (106-N, 108-N) are applied over the component (100), and this may be done while a cooling flow is also applied to the component (100). Then the preform material (110) is removed without destroying the new outer wall layers (106-N, 108-N). The new outer wall layers (106-N, 108-N) may be applied by HVOF processes or by other methods.

Abstract: A component for use in a combustion turbine (10) is provided that includes a substrate (212) and an abradable coating system (216) deposited on the substrate (212). A planar proximity sensor (250) may be deposited beneath a surface of the abradable coating system (216) having circuitry (252) configured to detect intrusion of an object (282) into the abradable coating system (216). A least one connector (52) may be provided in electrical communication with the planar proximity sensor (250) for routing a data signal from the planar proximity sensor (250) to a termination location (59). A plurality of trenches (142) may be formed at respective different depths below the surface of the abradable coating system (216) with a planar proximity sensor (250) deposited within each of the plurality of trenches (142).

Abstract: A layered abradable thermal barrier coating (TBC) 20 that is stable, abradabie, and sinter resistant up to about 1400° C. A tungsten bronze structured ceramic of the form Ba6?3xRE8+2xTi18O54, where 0<x<1.5, and RE represents a rare earth lanthanide cation, is applied as a topcoat over a yttria stabilized zirconia (YSZ) undercoat (18) on a bond-coated (17) superalloy metal structure (16). The tungsten bronze structure provides abradability and thermal conductivity. The YSZ layer is a proven concept for thermal barrier coatings, and has demonstrated better adhesion than newer chemistries This combination of layers has synergy that takes advantage of both materials to provide an abradable coating with an extended lifespan on a superalloy substrate compared to prior coatings. The topcoat may be applied with fugitive inclusions that produce porosity to increase abradabilty for improved blade tip clearance control in the turbine section of gas turbines.

Abstract: A method for making a gas turbine component (100). A central core (20) is positioned to occupy a space that will define a central channel (42), and an outer channel core (30) is positioned spaced apart from the central core (20). A mold (35) is formed around the central core (20) and the outer channel core (30), so that an exterior wall (32) contacts the mold (35). A substrate material, such as a metal alloy (247) in liquid form, is added to the mold (35) to form an internal volume (41) of the component (100). The central core (20) and the outer channel core (30) are removed, and interconnect channels (44) are formed between the thus-formed central channel (42) and the inner portion (49) of the outer channel (62) thus far formed. A preform (55) is placed into the inner portion (49) and may have a desired outer surface (57) shape. An overlay material is applied to form an outer layer (60), thus defining the remainder of the outer channel (62), which is obtained upon removal of the preform (55).

Abstract: A wear sensor (30, 50, 60) installed on a surface area (24) of a component (20, 21) subject to wear from an opposing surface (74, 75). The sensor has a proximal portion (32A, 52A, 62A) and a distal portion (32C, 52C, 62C) relative to a wear starting position (26). An electrical circuit (40) measures an electrical characteristic such as resistance of the sensor, which changes with progressive reduction of the sensor from the proximal portion to the distal portion during a widening reduction wear of the surface from the starting position. The measuring circuit quantifies the electrical changes to derive a wear depth based on a known geometry of the wear depth per wear width. In this manner, wear depth may be measured with a surface mounted sensor.

Abstract: A component for use in a combustion turbine (10) is provided that includes a substrate (212) and a microelectromechanical system (MEMS) device (50, 250) affixed to the substrate (212). At least one connector (52) may be deposited in electrical communication with the MEMS device (50, 250) for routing a data signal from the MEMS device (50, 250) to a termination location (59). A barrier coating (216) may be deposited on the substrate (212) wherein the MEMS device (50, 250) is affixed beneath a surface of the barrier coating (216). A plurality of trenches (142) may be formed in the barrier coating (216) at respective different depths below the surface of the barrier coating (216) and a MEMS device (50, 250) deposited within each of the plurality of trenches (142). A monitoring system (30) is provided that may include a processing module (34) programmed for receiving data from the MEMS device (50, 250).

Abstract: A catalyst element (30) for high temperature applications such as a gas turbine engine. The catalyst element includes a metal substrate such as a tube (32) having a layer of ceramic thermal barrier coating material (34) disposed on the substrate for thermally insulating the metal substrate from a high temperature fuel/air mixture. The ceramic thermal barrier coating material is formed of a crystal structure populated with base elements but with selected sites of the crystal structure being populated by substitute ions selected to allow the ceramic thermal barrier coating material to catalytically react the fuel-air mixture at a higher rate than would the base compound without the ionic substitutions. Precious metal crystallites may be disposed within the crystal structure to allow the ceramic thermal barrier coating material to catalytically react the fuel-air mixture at a lower light-off temperature than would the ceramic thermal barrier coating material without the precious metal crystallites.

Abstract: A telemetry system for use in a combustion turbine engine (10) having a compressor (12), a combustor and a turbine (16) that includes a sensor (50, 74) in connection with a turbine blade (18) or vane (22). A telemetry transmitter circuit (210) may be affixed to the turbine blade (18) with a first connecting material (52, 152) deposited on the turbine blade (18) for routing electronic data signals from the sensor (50, 74) to the telemetry transmitter circuit (210), the electronic data signals indicative of a condition of the turbine blade (18). An induction power system for powering the telemetry transmitter circuit (210) may include a rotating data antenna (202) affixed to the turbine blade (18) with a second connecting material (140) deposited on the turbine blade (18) for routing electronic data signals from the telemetry transmitter circuit (210) to the rotating data antenna (202).

Abstract: A thermal barrier coating (TBC) system (450) capable of self-healing has a substrate (420), a metal-based advanced bond coat (435) overlying the substrate and a ceramic top coat (440) overlying the bond coat. The bond coat (435) comprises ceramic oxide precursor materials capable of forming a non-alumina ceramic oxide composition when exposed to a thermally conditioning oxidizing environment. Embodiments of such bond coat (435) comprise rare earth elements in a range of 1-20 weight percent, and Hf in a range of about 5 to 30 weight percent or Zr in a range of about 2 to 20 weight percent. Examples of self-healing TBC systems (400, 402, 404) are provided using such bond coat (435) or its advanced bond coat chemistries in combination with conventional bond coats (433, 437) or conventional bond coat chemistries.

Abstract: A combustion turbine component (10) includes a combustion turbine component substrate (16) and an alloy coating (14) on the combustion turbine component substrate. The alloy coating (14) includes a first amount, by weight percent, of nickel (Ni) and a second amount, by weight percent, of cobalt (Co), the first amount being greater than the second amount. The alloy coating also includes chromium (Cr), aluminum (Al), and yttrium (Y). The alloy coating further includes at least one of titanium (Ti), tantalum (Ta), tungsten (W), and rhenium (Re). Moreover, the alloy coating includes at least one rare earth element, and an oxide of at least one of the yttrium the at least one rare earth element.

Abstract: A combustion turbine component (10) includes a combustion turbine component substrate (16) and an alloy coating (14) on the combustion turbine component substrate. The alloy coating (14) includes a first amount, by weight percent, of cobalt (Co) and a second amount, by weight percent, of nickel (Ni), the first amount being greater than the second amount. The alloy coating further includes chromium (Cr), aluminum (Al), at least one rare earth element, and an oxide of the at least one rare earth element.

Abstract: A combustion turbine component (10) includes a combustion turbine component substrate (16) and an alloy coating (14) on the combustion turbine component substrate. The alloy coating (14) includes nickel (Ni), chromium (Cr), aluminum (Al), and yttrium (Y). Furthermore, the alloy coating includes at least one of titanium (Ti), tantalum (Ta), tungsten (W), and rhenium (Re). The alloy coating also includes at least one rare earth element, and an oxide of at least one of the yttrium (Y) and the at least one rare earth element.

Abstract: A ceramic coating for imparting one or more of a variety of functional characteristics (e.g., reducing vibration levels) to one or more components or portions of an engine (e.g., ring segments, transition ducts, combustors, blades, vanes and shrouds of a turbine engine, portions thereof, and portions of a diesel engine), the components or portions comprising such a coating, and methods of making same. The ceramic coating exhibits a gradient or other change in the functional characteristic(s) through the thickness of the coating, across the surface area of the coating or both.

Abstract: A combustion turbine component (10) includes a combustion turbine component substrate (16) and an alloy coating (14) on the combustion turbine component substrate. The alloy coating (14) includes iron (Fe), chromium (Cr), aluminum (Al), at least one of titanium (Ti) and molybdenum (Mo), at least one rare earth element, and an oxide of the at least one rare earth element.

Abstract: A method of imparting one or more of a variety of functional characteristic to a portion of an engine (e.g., a turbine or diesel engine) by depositing particles from different particle feedstocks so as to form a high temperature resistant coating on a surface of the engine portion, where the particle feedstocks are varied in-situ while the particle are being deposited and at least one functional characteristic corresponds to, or results from, using different particle feedstocks.

Abstract: A ceramic thermal barrier coating (TBC) (18) having first and second layers (20, 22), the second layer (22) having a lower thermal conductivity than the first layer for a given density. The second layer may be formed of a material with anisotropic crystal lattice structure. Voids (24) in at least the first layer (20) make the first layer less dense than the second layer. Grooves (28) are formed in the TBC (18) for thermal strain relief. The grooves may align with fluid streamlines over the TBC. Multiple layers (84, 86,88) may have respective sets of grooves (90), Preferred failure planes parallel to the coating surface (30) may be formed at different depths (A1, A2, A3) in the thickness of the TBC to stimulate generation of a fresh surface when a portion of the coating fails by spalling. A dense top layer (92) may provide environmental and erosion resistance.

Abstract: The present invention provides near-surface cooled airfoils that can be made with near-surface cooling passages that are completely free of any leachable or otherwise sacrificial material in the recessed portion of the outer surface of the core. The turbine airfoil comprises a metallic core or substrate having an outer surface and one or a plurality of recessed portions of the outer surface; an intermediate metallic skin or foil having a back surface and a top surface, the back surface of the intermediate skin being bonded to the outer surface of the core such that the recessed portion(s) is sufficiently enclosed so as to form at least one or more near-surface cooling passages or pathways; and at least one or more metallic coatings of a high temperature-resistant metallic material deposited on a top surface of the intermediate skin.

Abstract: A thermal barrier coating (TBC) system (450) capable of self-healing has a substrate (420), a metal-based advanced bond coat (435) overlying the substrate and a ceramic top coat (440) overlying the bond coat. The bond coat (435) comprises ceramic oxide precursor materials capable of forming a non-alumina ceramic oxide composition when exposed to a thermally conditioning oxidizing environment. Embodiments of such bond coat (435) comprise rare earth elements in a range of 1-20 weight percent, and Hf in a range of about 5 to 30 weight percent or Zr in a range of about 2 to 20 weight percent. Examples of self-healing TBC systems (400, 402, 404) are provided using such bond coat (435) or its advanced bond coat chemistries in combination with conventional bond coats (433, 437) or conventional bond coat chemistries.

Abstract: System and computer program product for non-destructively inspecting and characterizing micro-structural features in a thermal barrier coating (TBC) on a component, wherein the micro-structural features define pores and cracks, if any, in the TBC. The micro-structural features having characteristics at least in part based on a type of process used for developing the TBC and affected by operational thermal loads to which a TBC is exposed. In one embodiment, the method allows detecting micro-structural features in a TBC, wherein the detecting of the micro-structural features is based on energy transmitted through the TBC, such as may be performed with a micro-feature detection system 20. The transmitted energy is processed to generate data representative of the micro-structural features, such as may be generated by a controller 26. The data representative of the micro-structural features is processed (e.g.

Abstract: An electrical assembly for use in various operating environments such as a casing of a combustion turbine 10 is provided. The assembly may include an electrical energy-harvesting device 51 disposed in a component within the casing of the turbine to convert a form of energy present within the casing to electrical energy. The harvesting device is configured to generate sufficient electrical power for powering one or more electrical devices therein without assistance from an external power source. One example of electrical devices wholly powered by the energy harvesting device may be a sensor 50 connected for sensing a condition of the component within the casing during operation of the combustion turbine. Another example of electrical devices wholly powered by the energy harvesting device may be a transmitter in communication with the sensor for wirelessly transmitting the data signal outside the casing.