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 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.

Abstract: A solid oxide fuel cell comprises at least one hollow manifold, an anode, an electrolyte, and a cathode. The at least one hollow manifold comprises a wall that defines a chamber therein. A plurality of openings extending through, such that the plurality of openings are in flow communication with the chamber. The anode is formed on an exterior surface of the wall. The electrolyte is deposited on the anode, and the cathode is deposited on the electrolyte.

Abstract: Disclosed herein are methods for forming casting molds. In one embodiment, a method for forming a mold comprises casting a mold having a cavity surface, forming surface features on the cavity surface, wherein the surface features comprise a mixture, and heat treating the mixture. In another embodiment an article is disclosed.

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: 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: A method for evaluating the thermal exposure of a selected metal component which has been exposed to changing temperature conditions is described. The voltage distribution on a surface of the metal component, or on a metallic layer which lies over the component, is first obtained. The voltage distribution usually results from a compositional change in the metal component. The voltage distribution is then compared to a thermal exposure-voltage model which expresses voltage distribution as a function of exposure time and exposure temperature for a reference standard corresponding to the metal component. In this manner, the thermal exposure of the selected component can be obtained. A related device for evaluating the thermal exposure of a selected metal component is also described.

Abstract: A system for measuring a condition of a turbine engine component comprises an assemblage of at least a film comprising an electrically conducting material disposed on a film of an electrically non-conducting material, the assemblage being disposed on a surface of the turbine engine component without removing material from the turbine engine component to compensate for thickness of at least one of the films. The electrically non-conducting material has a thermal expansion coefficient such that each of the films remains adhered to adjacent films through at least one cycle of extreme operating temperature. In addition, communication links can be provided to transmit the measurement representing the condition of the turbine engine to a remote user.

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 method of making an electrical cable, the method comprising: bonding a plurality of electrical conductors to respective neighboring ones of the electrical conductors to form a ribbon, the electrical conductors being electrically insulated from the respective neighboring ones; folding the ribbon to form cable assembly, each of the electrical conductors traversing the width of the cable assembly at least twice; optionally bonding the cable assembly; and optionally coiling the cable assembly.

Abstract: An abradable coating composition for use on shrouds in gas turbine engines or other hot gas path metal components exposed to high temperatures containing an initial porous coating phase created by adding an amount of inorganic microspheres, preferably alumina-ceramic microballoons, to a base metal alloy containing high Al, Cr or Ti such as ?-NiAl or, alternatively, MCrAlY that serves to increase the brittle nature of the metal matrix, thereby increasing the abradability and oxidation resistance of the coating at elevated temperatures. Coatings having a total open and closed porosity of between 20% and 55% by volume due to the presence of ceramic microballoons ranging in size from about 10 microns to about 200 microns have been found to exhibit excellent abradability for applications involving turbine shroud coatings. An abradable coating thickness in the range of between 40 and 60 ml provides improved performance for turbine shrouds exposed to gas temperatures between 1380° F. and 1800° F.

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: A method for forming a flow director on a component having a wall includes depositing at least one layer on the wall of the component. The deposition includes shaping the layer in accordance with a predetermined shape to form the flow director. An exemplary component is a turbine component with a wall having a cold surface and a hot surface. At least one film-cooling hole extends through the wall, for flowing a coolant from the cold surface to the hot surface, and defines an exit site in the hot surface of the wall. An exemplary deposition process includes delivering a mixture through a nozzle onto the wall to form the layer, where the mixture includes a powder dispersed in a liquid medium, displacing the nozzle relative to the wall and controlling the movement of the nozzle relative to the wall to form the layer in accordance with the predetermined shape.

Abstract: A method of making an electrical cable, the method comprising: bonding a plurality of electrical conductors to respective neighboring ones of the electrical conductors to form a ribbon, the electrical conductors being electrically insulated from the respective neighboring ones; folding the ribbon to form cable assembly, each of the electrical conductors traversing the width of the cable assembly at least twice; optionally bonding the cable assembly; and optionally coiling the cable assembly.

Abstract: An abradable coating composition for use on shrouds in gas turbine engines or other hot gas path metal components exposed to high temperatures containing an initial porous coating phase created by adding an amount of inorganic microspheres, preferably alumina-ceramic microballoons, to a base metal alloy containing high Al, Cr or Ti such as &bgr;-NiAl or, alternatively, MCrAlY that serves to increase the brittle nature of the metal matrix, thereby increasing the abradability and oxidation resistance of the coating at elevated temperatures. Coatings having a total open and closed porosity of between 20% and 55% by volume due to the presence of ceramic microballoons ranging in size from about 10 microns to about 200 microns have been found to exhibit excellent abradability for applications involving turbine shroud coatings. An abradable coating thickness in the range of between 40 and 60 ml provides improved performance for turbine shrouds exposed to gas temperatures between 1380° F. and 1800° F.

Abstract: A method to apply a material layer, comprises selecting a first material with a first melting temperature and a second material composition having a second melting temperature at least 40° C. lower than the first melting temperature; forming a suspension comprising the first material and second material composition in a carrier medium; depositing the suspension onto a surface to form a layer; and controllably heating the layer to a temperature at least 20° C. above the melting temperature of the second material composition but no higher than 20° C. below the melting temperature of the first material, to dissolve at least some of the first material in melted second material composition. A composition of matter, comprises a first material with a first melting temperature and a second material composition having a second melting temperature at least 40° C. lower than the first melting temperature and a carrier medium.

Abstract: A gas turbine engine comprises (A) a turbine including a nozzle and shroud assembly supported within the engine; the nozzle and shroud assembly including an inner annular ring member, an outer annular ring structure and a plurality of airfoils being positioned between the inner and outer ring structure, wherein at least one of the airfoils of the plurality comprises; (i) a substrate comprising a first electrically conducting material; and (ii) a wire of dissimilar electrically conducting material extending a measured distance in intimate contact with the substrate at a reference point and electrically insulated to a measuring point.

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: A solid oxide fuel cell comprises at least one hollow manifold, an anode, an electrolyte, and a cathode. The at least one hollow manifold comprises a wall that defines a chamber therein. A plurality of openings extending through, such that the plurality of openings are in flow communication with the chamber. The anode is formed on an exterior surface of the wall. The electrolyte is deposited on the anode, and the cathode is deposited on the electrolyte.

Abstract: A system for measuring a condition of a turbine engine component comprises an assemblage of at least a film comprising an electrically conducting material disposed on a film of an electrically non-conducting material, the assemblage being disposed on a surface of the turbine engine component without removing material from the turbine engine component to compensate for thickness of at least one of the films. The electrically non-conducting material has a thermal expansion coefficient such that each of the films remains adhered to adjacent films through at least one cycle of extreme operating temperature. In addition, communication links can be provided to transmit the measurement representing the condition of the turbine engine to a remote user.