Abstract: A thermal barrier coating (TBC) with depth-varying material properties is formed on a turbine component. Exemplary depth-varying material properties include physical ductility, strength and thermal resistivity that vary from the TBC layer inner to outer surface. Exemplary ways to modify physical properties include application of plural separate overlying layers of different material composition or by varying the applied material composition during the application of the TBC layer. Various embodiment described herein also apply a calcium-magnesium-aluminum-silicon (CMAS)-retardant material over the TBC layer to retard reaction with or adhesion of CMAS containing combustion particulates to the TBC layer. In other embodiments the CMAS retardant material is also applied within engineered groove features (EGFs) that are formed in the TBC surface.

Abstract: Engineered groove features (EGFs) are formed within thermal barrier coatings (TBCs) of turbine engine components. The EGFs are advantageously aligned with likely stress zones within the TBC or randomly aligned in a convenient two-dimensional or polygonal planform pattern on the TBC surface and into the TBC layer. The EGFs localize thermal stress- or foreign object damage (FOD)-induced crack propagation within the TBC that might otherwise allow excessive TBC spallation and subsequent thermal exposure damage to the turbine component underlying substrate. Propagation of a crack is arrested when it reaches an EGF, so that it does not cross over the groove to otherwise undamaged zones of the TBC layer. In some embodiments, the EGFs are combined with engineered surface features (ESFs) that are formed in the component substrate or within intermediate layers applied between the substrate and the TBC.

Abstract: A turbine abradable component includes a support surface and a thermally sprayed ceramic/metallic abradable substrate coupled to the support surface for orientation proximal a rotating turbine blade tip circumferential swept path. An elongated pixelated major planform pattern (PMPP) of a plurality of discontinuous micro surface features (MSF) project from the substrate surface. The PMPP repeats radially along the swept path in the blade tip rotational direction, for selectively directing airflow between the blade tip and the substrate surface. Each MSF is defined by a pair of first opposed lateral walls defining a width, length and height that occupy a volume envelope of 1-12 cubic millimeters. The PMPP arrays of MSFs provide airflow control of hot gasses in the gap between the abradable surface and the blade tip with smaller potential rubbing surface area than solid projecting ribs with similar planform profiles.

Abstract: Thermal barrier coatings (TBCs) for turbine engine components are applied over engineered surface features (ESFs) that are formed in the component substrate or within intermediate layers applied between the substrate and the TBC. The ESFs help anchor the TBC layer and/or localize cracks that are bounded by one or more of the ESFs. During engine operation the ESFs arrest thermal stress-or foreign object damage (FOD)-induced crack propagation within the TBC that might otherwise allow excessive TBC spallation and subsequent thermal exposure damage to the turbine component underlying substrate. In some embodiments, the ESFs are combined with engineered groove features that are formed in the TBC.

Abstract: A thermal barrier coating (TBC) with depth-varying material properties is formed on a turbine component. Exemplary depth-varying material properties include physical ductility, strength and thermal resistivity that vary from the TBC layer inner to outer surface. Exemplary ways to modify physical properties include application of plural separate overlying layers of different material composition or by varying the applied material composition during the application of the TBC layer. Various embodiment described herein also apply a calcium-magnesium-aluminum-silicon (CMAS)-retardant material over the TBC layer to retard reaction with or adhesion of CMAS containing combustion particulates to the TBC layer. In other embodiments the CMAS retardant material is also applied within engineered groove features (EGFs) that are formed in the TBC surface.

Abstract: Engineered groove features (EGFs) are formed within thermal barrier coatings (TBCs) of turbine engine components. The EGFs are advantageously aligned with likely stress zones within the TBC or randomly aligned in a convenient two-dimensional or polygonal planform pattern on the TBC surface and into the TBC layer. The EGFs localize thermal stress- or foreign object damage (FOD)-induced crack propagation within the TBC that might otherwise allow excessive TBC spallation and subsequent thermal exposure damage to the turbine component underlying substrate. Propagation of a crack is arrested when it reaches an EGF, so that it does not cross over the groove to otherwise undamaged zones of the TBC layer. In some embodiments, the EGFs are combined with engineered surface features (ESFs) that are formed in the component substrate or within intermediate layers applied between the substrate and the TBC.

Abstract: A method of manufacturing a superalloy compound component is provided. The component includes a first component portion primarily consisting of a first superalloy and a second component portion primarily consisting of a second superalloy or of a refractory metal. The method includes using Spark Plasma Sintering for forming the superalloy compound component.

Abstract: A powder-based material system having an intrinsic and stable degree of porosity provided by hollow ceramic spheres (26) in a fully dense matrix (27). A substrate (22) is formed from a metal powder (70), and may be partially sintered (60). A layer (24) of ceramic powder is arranged on the substrate including the pre-sintered hollow ceramic spheres plus a proportion of nano-sized ceramic particles effective to reduce the layer sintering temperature and to increase the sintering shrinkage of the layer to approximate that of the metal substrate during subsequent co-sintering. The substrate and layer are then co-sintered (61), such as with spark plasma sintering (32, 34, 36), at a temperature and for a duration to fully densify the ceramic powder matrix around the hollow spheres, thereby producing a metal/ceramic material system with low interface stress and with stable porosity during operational temperatures in a gas turbine engine.

Abstract: An inductance-stable ultra high temperature circuit coupling transformer (50) used to transmit and receive alternating current power and/or data signals (29?, 33?). Primary (30?) and secondary (34?) windings are formed on nanostructured laminated (31?) primary and secondary steel cores (32?) having a Curie temperature exceeding an ultra high operating temperature. The operating range can extend from ambient to 250° C. or to in excess of 550° C. or up to 700° C. with a change in inductance of less than 10% in various embodiments.

Abstract: A thermal barrier tile (34) with a braze layer (46) co-sintered to a ceramic layer (48) is brazed to a substrate (26) of a component for fabrication or repair of a thermal barrier coating (28) for example on a gas turbine ring segment (22, 24). The tile may be fabricated by disposing a first layer of a metal brazing material in a die case (40); disposing a second layer of a ceramic powder on the metal brazing material; and co-sintering the two layers with spark plasma sintering to form the co-sintered ceramic/metal tile. A material property of an existing thermal barrier coating to be repaired may be determined (90), and the co-sintering may be controlled (93) responsive to the property to produce tiles compatible with the existing thermal barrier coating in a material property such as thermal conductivity.

Abstract: A manufacturing method for manufacturing a slice for making or repairing a heat protective coating of a hot gas path component of a gas turbine is provided. The manufacturing method includes debinding a prepreg made of at least two sheets containing powder bound by a binder and Spark Plasma Sintering the at least two debound sheets.

Abstract: A method of forming a ceramic layer on a metal substrate. A substrate (40) is formed (54) from a powder (24) of the metal, and may optionally be partially sintered (56). A layer (43) of powdered ceramic is formed (58) on or applied against the substrate (45). The ceramic powder may include a proportion of nano-sized particles effective to reduce the ceramic sintering temperature and to increase the sintering shrinkage of the ceramic layer to more closely match that of the metal substrate. The substrate and layer are then co-sintered (21, 60) at a temperature and for a duration that densifies and bonds them, producing a metal/ceramic layered material system with low interface stress that is durable to temperature variations in a gas turbine. Spark plasma sintering (32, 34, 36) may be used to sinter and/or co-sinter substrate and layer materials that normally cannot be sintered.

Abstract: A voltage regulator circuitry (50) adapted to operate in a high-temperature environment of a turbine engine is provided. The voltage regulator may include a constant current source (52) including a first semiconductor switch (54) and a first resistor (56) connected between a gate terminal (G) and a source terminal (S) of the first semiconductor switch. A second resistor (58) is connected to the gate terminal of the first semiconductor switch (54) and to an electrical ground (64). The constant current source is coupled to generate a voltage reference across the second resistor 58. A source follower output stage 66 may include a second semiconductor switch (68) and a third resistor (58) connected between the electrical ground and a source terminal of the second semiconductor switch. The generated voltage reference is applied to a gating terminal of the second semiconductor switch (58).

Abstract: Turbine and compressor casing abradable component embodiments for turbine engines, with composite grooves and vertically projecting rows of ridges in planform patterns, establishing upper and lower wear zones. The lower wear zone reduces, redirects and/or blocks blade tip downstream airflow leakage, while the upper wear zone is optimized to minimize blade tip gap and wear by being more easily abradable than the lower zone. An elongated first ridge in the lower wear zone terminates in a continuous surface plateau. A plurality of second ridges or nibs, separated by grooves, project from the plateau, forming the upper wear zone. Each of the second ridges has a planform cross section smaller than the plateau planform cross section and a height smaller than the first ridge height. Some embodiments of the second ridges have spacing, planform cross sections, heights and separating groove dimensions selected for shearing when contacted by turbine blade tips.

Abstract: A thermal barrier tile (34) with a braze layer (46) co-sintered to a ceramic layer (48) is brazed to a substrate (26) of a component for fabrication or repair of a thermal barrier coating (28) for example on a gas turbine ring segment (22, 24). The tile may be fabricated by disposing a first layer of a metal brazing material in a die case (40); disposing a second layer of a ceramic powder on the metal brazing material; and co-sintering the two layers with spark plasma sintering to form the co-sintered ceramic/metal tile. A material property of an existing thermal barrier coating to be repaired may be determined (90), and the co-sintering may be controlled (93) responsive to the property to produce tiles compatible with the existing thermal barrier coating in a material property such as thermal conductivity.

Abstract: A circuitry adapted to operate in a high-temperature environment of a turbine engine is provided. A relatively high-gain differential amplifier (102) may have an input terminal coupled to receive a voltage indicative of a sensed parameter of a component (20) of the turbine engine. A hybrid load circuitry may be coupled to the differential amplifier. A voltage regulator circuitry (244) may be coupled to power the differential amplifier. The differential amplifier, the hybrid load circuitry and the voltage regulator circuitry may each be disposed in the high-temperature environment of the turbine engine.

Abstract: A circuitry (120) adapted to operate in a high-temperature environment of a turbine engine is provided. The circuitry may include a differential amplifier (122) having an input terminal (124) coupled to a sensing element to receive a voltage indicative of a sensed parameter. A hybrid load circuitry (125) may be AC-coupled to the differential amplifier. The hybrid load circuitry may include a resistor-capacitor circuit (134) arranged to provide a path to an AC signal component with respect to the drain terminal of the switch (e.g., 126) of a differential pair of semiconductor switches 126, 128, which receives the voltage indicative of the sensed parameter.

Abstract: Chopper circuitry may be adapted to operate in a high-temperature environment of a turbine. A first semiconductor switch (122) may have a first terminal coupled to receive a first output signal from a first leg (148) of a differential amplifier (150). A second switch (128) may have a first terminal coupled thru a first resistive element (R1) to a second terminal of the first semiconductor switch. The first terminal of the second semiconductor switch may be coupled to receive thru a second resistive element (R2) a second output signal from a second leg (152) of the amplifier. Switches (122,128) may be responsive to a switching control signal to respective gate terminals of the switches to supply an output signal, which alternates in correspondence with a frequency of the switching control signal from a first amplitude level to a second amplitude level, which effectively provides a doubling amplification factor.

Abstract: A double-sided adhesive metal-based tape for use as contacting aid for SOFC fuel cells is provided. The double-sided metal-based adhesive tape is suitable for simplifying the construction of cell bundles. The double-sided metal-based adhesive tape is used for electrical contacting of the cell connector with the anode and for electrical contacting of the interconnector of the fuel cells with the cell connector. A method for producing the double-sided adhesive metal-base tape is also provided.

Abstract: Chopper circuitry may be adapted to operate in a high-temperature environment of a turbine. A first semiconductor switch (122) may have a first terminal coupled to receive a first output signal from a first leg (148) of a differential amplifier (150). A second switch (128) may have a first terminal coupled thru a first resistive element (R1) to a second terminal of the first semiconductor switch. The first terminal of the second semiconductor switch may be coupled to receive thru a second resistive element (R2) a second output signal from a second leg (152) of the amplifier. Switches (122,128) may be responsive to a switching control signal to respective gate terminals of the switches to supply an output signal, which alternates in correspondence with a frequency of the switching control signal from a first amplitude level to a second amplitude level, which effectively provides a doubling amplification factor.