Abstract: Methods of reducing an initial cross-sectional area of a hole in a component to a predetermined cross-sectional area including preparing a composition comprising at least an aluminum alloy with a melting temperature higher than aluminum, applying the composition to an interior surface of the hole, and then heating the component to cause a metal within the component to diffuse from the component into the composition and react with the aluminum alloy in the composition to form a coating on the interior surface of the hole. The heating step is performed to selectively modify the initial cross-sectional area of the hole and thereby directly attain the predetermined cross-sectional area thereof.

Abstract: Methods of reducing an initial cross-sectional area of a hole in a component to a predetermined cross-sectional area including preparing a composition comprising at least an aluminum alloy with a melting temperature higher than aluminum, applying the composition to an interior surface of the hole, and then heating the component to cause a metal within the component to diffuse from the component into the composition and react with the aluminum alloy in the composition to form a coating on the interior surface of the hole. The heating step is performed to selectively modify the initial cross-sectional area of the hole and thereby directly attain the predetermined cross-sectional area thereof.

Abstract: A gas turbine or turbine component partially or fully coated with a damping surface layer. The damping surface layer may have a thickness between 0.1 and 2000 microns and may be capable of dissipating vibration or modifying a resonance frequency of the gas turbine or turbine component at ambient room temperatures including operational temperatures greater than 500° F., and the damping surface layer comprises at least one of (a) at least two layers comprising a first layer of at least one hard material and a second layer comprising at least one soft material, (b) a composite comprising a nickel alloy with a heat softenable chemistry, (c) a fine-grained nickel-based superalloy, or (d) a porous metallic coating, a porous metallic and ceramic coating, or a ceramic coating.

Abstract: The present invention provides high-throughput systems and methods for the fabrication and evaluation of electrode and electrolyte materials for solid oxide fuel cells. The present invention includes systems and methods for synthesizing and optimizing the performance of electrodes and electrode-electrolyte combinations and utilizes small-scale techniques to perform such optimization based on chemical composition and variable processing. Advantageously, rapid device performance systems and methods coupled with structural and surface systems and methods allow for an increased discovery rate of new materials for solid oxide fuel cells.

Abstract: A method of forming at least one concavity of a selected size and shape within a surface of an internal passageway of a metallic component comprises: depositing a ceramic-based material by a direct-write technique onto a ceramic core which is suitable for forming the internal passageway during a casting process to form the metallic component, wherein the ceramic-based material is deposited as a positive feature; heat-treating the deposited ceramic-based material; forming the metallic component by a casting process in which the ceramic core is incorporated into the casting, in a position selected as a desired position for the internal passageway; and then removing the ceramic core from the metal component after the casting process is complete, thereby forming the internal passageway, with the concavity contained within the surface of the passageway, said concavity formed by removal of the positive feature of the ceramic-based material.

Abstract: Multi-layer sensors are made using a direct write deposition technology. The sensors are formed on the surface of an object having a system characteristic to be monitored, such as temperature and strain. A first layer is deposited onto the substrate of the object to be monitored, a second layer is deposited onto the first layer, and a third layer is deposited onto the second layer. An optional protective layer may be deposited between the first layer and the substrate to prevent chemical interaction and lack of adhesion therebetween. A glazing or glassing layer may also be deposited to protect the thermistor from the operating environment to keep its electrical properties constant. These layers are sintered together, then electrical leads are attached to the sensor and to a monitoring controller. The monitoring controller may be hardwired to the sensor or remote therefrom.

Abstract: A method of forming at least one concavity of a selected size and shape within a surface of an internal passageway of a metallic component comprises: depositing a ceramic-based material by a direct-write technique onto a ceramic core which is suitable for forming the internal passageway during a casting process to form the metallic component, wherein the ceramic-based material is deposited as a positive feature; heat-treating the deposited ceramic-based material; forming the metallic component by a casting process in which the ceramic core is incorporated into the casting, in a position selected as a desired position for the internal passageway; and then removing the ceramic core from the metal component after the casting process is complete, thereby forming the internal passageway, with the concavity contained within the surface of the passageway, said concavity formed by removal of the positive feature of the ceramic-based material.

Abstract: A system is provided for contaminant removal. The system includes an inlet for transmitting a contaminated solution and a reverse osmosis membrane having at least one flow modifier. The reverse osmosis membrane is configured to separate condensate and permeate from the contaminated solution. The system also includes a porous central tube for carrying the permeate and an outlet for the condensate. A method is also provided for removing contaminants from a solution.

Abstract: An alloy for an interconnect for a fuel cell is provided. The alloy comprises iron at least about 60 weight percent, chromium in the range of about 15 to about 30 weight percent and tungsten in the range of about 3 to about 4.5 weight percent. The alloy also includes at least one element selected from the group consisting of aluminum, yttrium, zirconium, lanthanum, manganese, molybdenum, nickel, vanadium, tantalum, and titanium.

Abstract: A device for measuring at least one property of a material sample is disclosed. The device includes at least one sensor element which is formed by a direct-write technique. The device can be an instrument for measuring strain in the sample, or for measuring other properties or attributes of a sample, such as temperature. A turbine engine disk on which components of property-measuring devices have been direct-written is also described. Methods of forming sensor elements for property-measuring devices are disclosed.

Abstract: A method for making a microfluidic device comprises providing a processing substrate, forming a negative stamp on the processing substrate using a direct write process, disposing a coating material on the processing substrate, curing the coating material to produce a cured coating material, and separating the processing substrate and the negative stamp from the cured coating material, wherein a plurality of channels are formed in the cured coating material corresponding to a location of the negative stamp.

Abstract: Disclosed herein is a turbine component comprising a substrate; and a protective structure formed on the substrate, wherein the protective structure comprises an ?-? titanium alloy, a ?-titanium alloy or a near-? titanium alloy. Disclosed herein too is a process for providing a protective structure to a turbine component, comprising affixing a protective structure on a turbine component; wherein the protective structure comprises an ?-? titanium alloy, a near-? titanium alloy or a ?-titanium alloy.

Abstract: Multi-layer sensors are made using a direct write deposition technology. The sensors are formed on the surface of an object having a system characteristic to be monitored, such as temperature and strain. A first layer is deposited onto the substrate of the object to be monitored, a second layer is deposited onto the first layer, and a third layer is deposited onto the second layer. An optional protective layer may be deposited between the first layer and the substrate to prevent chemical interaction and lack of adhesion therebetween. A glazing or glassing layer may also be deposited to protect the thermistor from the operating environment to keep its electrical properties constant. These layers are sintered together, then electrical leads are attached to the sensor and to a monitoring controller. The monitoring controller may be hardwired to the sensor or remote therefrom.

Abstract: Multi-layer sensors are made using a direct write deposition technology. The sensors are formed on the surface of an object having a system characteristic to be monitored, such as temperature and strain. A first layer is deposited onto the substrate of the object to be monitored, a second layer is deposited onto the first layer, and a third layer is deposited onto the second layer. An optional protective layer may be deposited between the first layer and the substrate to prevent chemical interaction and lack of adhesion therebetween. A glazing or glassing layer may also be deposited to protect the thermistor from the operating environment to keep its electrical properties constant. These layers are sintered together, then electrical leads are attached to the sensor and to a monitoring controller. The monitoring controller may be hardwired to the sensor or remote therefrom.

Abstract: An erosion resistant protective structure for a turbine engine component comprises a shape memory alloy. The shape memory alloy includes nickel-titanium based alloys, indium-titanium based alloys, nickel-aluminum based alloys, nickel-gallium based alloys, copper based alloys, gold-cadmium based alloys, iron-platinum based alloys, iron-palladium based alloys, silver-cadmium based alloys, indium-cadmium based alloys, manganese-copper based alloys, ruthenium-niobium based alloys, ruthenium-tantalum based alloys, titanium based alloys, iron-based alloys, or combinations comprising at least one of the foregoing alloys. Also, disclosed herein are methods for forming the shape memory alloy onto turbine component.

Abstract: Method of producing a profiled abradable coating on a substrate in which an abradable ceramic coating composition is applied to a substrate using direct-write technology, or plasma sprayed onto the substrate through a mask or by use of a narrow foot-print plasma gun. These methods of producing abradable coatings are performed in the absence of a grid.

Abstract: An alloy, an article comprising the alloy, and methods for manufacturing and repairing an article that employ the alloy are presented. The alloy comprises, in atom percent, at least about 50% rhodium, up to about 49% of a first material, from about 1% to about 15% of a second material, and up to about 10% of a third material. The first material comprises at least one of palladium, platinum, iridium, and combinations thereof. The second material comprises at least one of tungsten, rhenium, and combinations thereof. The third material comprises at least one of ruthenium, chromium, and combinations thereof. The alloy comprises an A1-structured phase at temperatures greater than about 1000° C., in an amount of at least about 90% by volume.

Abstract: A component includes a wall with a cold and a hot surface. At least one film-cooling hole extends through the wall for flowing a coolant from the cold to the hot surface. The film-cooling hole defines an exit site in the hot surface. At least one flow modifier is formed on the hot surface and is adapted to direct the coolant flowing from the film-cooling hole and out of the exit site toward the hot surface. The flow modifier extends outwards from and conforms to the hot surface. A turbine assembly includes a first and a second component that define a secondary cooling slot, which receives and guides a secondary coolant flow. At least one flow modifier is formed on a surface of one of the two components and is adapted to enhance the secondary coolant flow along at least one of the two components within the secondary coolant slot.

Abstract: A combustor and combustor liner cap assembly for reducing noise emissions and acoustic dynamics during operation of a gas turbine generally includes a cellular solid media disposed in the combustor liner cap assembly. The cellular solid media absorbs noise emissions and acoustic dynamics, thereby reducing stresses and vibrations on the combustor assembly associated with operation of the gas turbine.

Abstract: A robotic pen includes a computer numerically controlled machine having a multiaxis stage for mounting a workpiece, and a cooperating elevator which translates relative thereto. A pen tip is rotatably mounted to the elevator. And, a dispenser is joined in flow communication with the pen tip for ejecting a stream of material atop the workpiece as the workpiece moves relative thereto for maintaining a substantially constant gap between said pen tip and the workpiece during relative movement therebetween.