Abstract: A cooling system for a transition duct for routing a gas flow from a combustor to the first stage of a turbine section in a combustion turbine engine is disclosed. The transition duct may have a multi-panel outer wall formed from an inner panel having an inner surface that defines at least a portion of a hot gas path plenum and an intermediate panel positioned radially outward from the inner panel such that at least one cooling chamber is formed between the inner and intermediate panels. The transition duct may also include an outer panel. The inner, intermediate and outer panels may include one or more metering holes for passing cooling fluids between cooling chambers for cooling the panels. The intermediate and outer panels may be secured with an attachment system coupling the panels to the inner panel such that the intermediate and outer panels may move in-plane.

Abstract: A cooling system for a transition duct for routing a gas flow from a combustor to the first stage of a turbine section in a combustion turbine engine is disclosed. The transition duct may have a multi-panel outer wall formed from an inner panel having an inner surface that defines at least a portion of a hot gas path plenum and an intermediate panel positioned radially outward from the inner panel such that at least one cooling chamber is formed between the inner and intermediate panels. The transition duct may also include an outer panel. The inner, intermediate and outer panels may include one or more metering holes for passing cooling fluids between cooling chambers for cooling the panels. The intermediate and outer panels may be secured with an attachment system coupling the panels to the inner panel such that the intermediate and outer panels may move in-plane.

Abstract: A turbine airfoil usable in a turbine engine with a cooling system and a compliant dual wall configuration configured to enable thermal expansion between inner and outer layers while eliminating stress formation in the outer layer is disclosed. The compliant dual wall configuration may be formed a dual wall formed from inner and outer layers separated by a support structure. The outer layer may be a compliant layer configured such that the outer layer may thermally expand and thereby reduce the stress within the outer layer. The outer layer may be formed from a nonplanar surface configured to thermally expand. In another embodiment, the outer layer may be planar and include a plurality of slots enabling unrestricted thermal expansion in a direction aligned with the outer layer.

Abstract: A stack of substantially parallel ceramic plates (22) separated and interconnected by ceramic spacers (26, 27) forming a seal structure (20) with a length (L), a width (W), and a thickness (T). The spacers are narrower in width than the plates, and may be laterally offset from spacers in adjacent rows to form a space (28) in a row that aligns with a spacer in another adjacent row. An adjacent plate bends into the space when the seal structure is compressed in thickness. The spacers may have gaps (60, 62) forming a stepped or labyrinthine cooling flow path (66) within the seal structure. The spacers of each row may vary in lateral separation, thus providing a range of compressibility that varies along the width of the seal structure.

Abstract: A ceramic matrix composite (CMC) component such as a ring seal segment (50, 50A, 50B, 50C, 50D) for a gas turbine engine (10), the component formed with a base plate (52) and a frame portion (54) that extends substantially normally from the base plate around its perimeter. A grid of intersecting CMC ribs (73) is formed on the base plate within the frame portion. The ribs have a height (H) that may be within 3 times the total thickness (B) of the base plate, including any rib base (39) bonded to the base plate, along at least most of the rib length. The grid of ribs may be assembled from an array of CMC cups (40) bonded to the base plate, to adjacent cups, and to the frame portion.

Abstract: A cooled component wall (52) with a combustion gas (36) on one side (56) and a coolant gas (48) with higher pressure on the other side (58). The wall includes a cooling chamber (60) with an impingement cooling zone (62), a convective cooling zone (64), and a film cooling zone (66). Impingement holes (70) admit and direct jets (72) of coolant against the wall, thence the coolant passes among heat transfer elements such as channels (76) and fins (78) to the film cooling zone (66) where it passes through holes in the wall that direct a film of the coolant along the combustion side of the wall. The chamber may be oriented with the impingement zone (62) downstream and the film cooling zone (66) upstream, relative to the combustion gas flow (36). This provides two passes of the coolant (84, 79) in opposite directions over the respective opposite sides of the wall (56, 58).

Abstract: A conduit through which hot combustion gases pass in a gas turbine engine. The conduit includes a wall structure having an inner surface, an outer surface, a region, an inlet, and an outlet. The inner surface defines an inner volume of the conduit. The region extends between the inner and outer surfaces and includes cooling fluid structure defining a plurality of cooling passageways. The inlet extends inwardly from the outer surface and provides fluid communication between the inlet and the passageways. The outlet extends from the passageways to the inner surface to provide fluid communication between the passageways and the inner volume. At least one first cooling passageway intersects with at least one second cooling passageway such that cooling fluid flowing through the first cooling passageway interacts with cooling fluid flowing through the second cooling passageway.

Abstract: A method of making a combustion turbine component includes forming a metallic body by direct metal fabrication (DMF) to have at least one surface portion defining a first plurality of surface cooling features each having a first dimension and at least one second surface cooling feature on at least one of the first plurality of surface cooling features and having a second dimension less than said first dimension and less than 200 ?m. Forming the metallic body by DMF may include forming a plurality of metallic combustion turbine subcomponent greenbodies by DMF and assembling the plurality of metallic combustion turbine subcomponent greenbodies together to form a metallic greenbody assembly. The metallic greenbody assembly may be sintered to thereby form the metallic body.

Abstract: A turbine airfoil usable in a turbine engine with a cooling system and a compliant dual wall configuration configured to enable thermal expansion between inner and outer layers while eliminating stress formation is disclosed. The compliant dual wall configuration may be formed a dual wall formed from inner and outer layers separated by a compliant structure. The compliant structure may be configured such that the outer layer may thermally expand without limitation by the inner layer. The compliant structure may be formed from a plurality of pedestals positioned generally parallel with each other. The pedestals may include a first foot attached to a first end of the pedestal and extending in a first direction aligned with the outer layer, and may include a second foot attached to a second end of the pedestal and extending in a second direction aligned with the inner layer.

Abstract: An attachment method and flange for connecting a ceramic matrix composite (CMC) component, such as a gas turbine shroud ring (36, 68), to a metal support structure. A CMC flange (20A) may be formed by attaching a wedge-shaped block (26) of a ceramic material to a CMC wall structure (22), and wrapping CMC layers (24) of the wall structure (22) at least partly around the block (26), forming the flange (20A) with an inner oblique face (34) and an outer face (35) normal to the wall structure. An adjacent support structure, such as a metal support ring (40A), may abut the outer face (35) of the CMC flange (20A) and be clamped or bolted to the CMC flange (20A).

Abstract: A gusset (40A-G) between two CMC walls (26, 28) has fibers (23) oriented to provide anisotropic strengthening of the wall intersection (34). The fibers (23) may be oriented diagonally to oppose in tension a wall-spreading moment of the walls (26, 28) about the intersection (34). Interlocking features (46, 48, 52, 56, 58) may be provided on the gusset to improve load sharing between the gusset and the walls. The gusset may have one or more diagonal edges (50, 51) that contact matching edges of a slot (42, 42D, 43D) to oppose wall-spreading (M1) and wall-closing (M2) bending of the walls (26, 28). The gusset may be installed in the slot after preparing the gusset and the walls to different temperatures. Then the assembly may be final-fired to produce differential shrinkage that causes compression of the gusset or the wall intersection.

Abstract: A turbine airfoil (31) with an end portion (42) that tapers (44) toward the end (43) of the airfoil. A ridge (46) extends around the end portion. It has proximal (66) and distal (67) sides. A shroud platform (50) is bi-cast onto the end portion around the ridge without bonding. Cooling shrinks the platform into compression (62) on the end portion (42) of the airfoil. Gaps between the airfoil and platform are formed using a fugitive material (56) in the bi-casting stage. These gaps are designed in combination with the taper angle (44) to accommodate differential thermal expansion while maintaining a gas seal along the contact surfaces. The taper angle (44) may vary from lesser on the pressure side (36) to greater on the suction side (38) of the airfoil. A collar portion (52) of the platform provides sufficient contact area for connection stability.

Abstract: An arrangement (10) for conveying combustion gas from a plurality of can annular combustors to a turbine first stage blade section of a gas turbine engine, the arrangement (10) including a plurality of interconnected integrated exit piece (IEP) sections (16) defining an annular chamber (18) oriented concentric to a gas turbine engine longitudinal axis (20) upstream of the turbine first stage blade section. Each respective IEP (16) includes a first flow path section (40) receiving and fully bounding a first flow from a respective can annular combustor along a respective common axis (22) there between, and delivering a partially bounded first flow to a downstream adjacent IEP section (42). Each respective IEP further includes a second flow path section (112) receiving a partially bounded second flow from an upstream adjacent IEP (66) and delivering at least part of the second flow to the turbine first stage blade section.

Abstract: A turbine airfoil (22A) is formed by a first process using a first material. A platform (30A) is formed by a second process using a second material that may be different from the first material. The platform (30A) is assembled around a shank (23A) of the airfoil. One or more pins (36A) extend from the platform into holes (28) in the shank (23A). The platform may be formed in two portions (32A, 34A) and placed around the shank, enclosing it. The two platform portions may be bonded to each other. Alternately, the platform (30B) may be cast around the shank (23B) using a metal alloy with better castability than that of the blade and shank, which may be specialized for thermal tolerance. The pins (36A-36D) or holes for them do not extend to an outer surface (31) of the platform, avoiding stress concentrations.

Abstract: A ceramic hybrid structure (207, 502, 602, 608) that includes a wavy ceramic matrix composite (CMC) wall (214, 532, 603, 609) bonded with a ceramic insulating layer (230, 538, 604, 610) having a distal surface (242) that may define a hot gas passage (250, 550, 650) or otherwise be in proximity to a source of elevated temperature. In various embodiments, the waves (216, 537, 637) of the CMC wall (214, 532, 603, 609) may conform to the following parameters: a thickness (222) between 1 and 10 millimeters; an amplitude (224) between one and 2.5 times the thickness; and a period (226) between one and 20 times the amplitude. The uninsulated backside surface (218) of the CMC wall (214) provides a desired stiffness and strength and enhanced cooling surface area. In various embodiments the amplitude (224), excluding the thickness (222), may be at least 2 mm.

Abstract: A stem (34) extends from a second part (30) through a hole (28) in a first part (22). A groove (38) around the stem provides a non-threaded contact surface (42) for a ring element (44) around the stem. The ring element exerts an inward force against the non-threaded contact surface at an angle that creates axial tension (T) in the stem, pulling the second part against the first part. The ring element is formed of a material that shrinks relative to the stem by sintering. The ring element may include a split collet (44C) that fits partly into the groove, and a compression ring (44E) around the collet. The non-threaded contact surface and a mating distal surface (48) of the ring element may have conic geometries (64). After shrinkage, the ring element is locked onto the stem.

Abstract: A method of making a combustion turbine component includes forming a metallic body by direct metal fabrication (DMF) to have at least one surface portion defining a first plurality of surface cooling features each having a first dimension and at least one second surface cooling feature on at least one of the first plurality of surface cooling features and having a second dimension less than said first dimension and less than 200 ?m. Forming the metallic body by DMF may include forming a plurality of metallic combustion turbine subcomponent greenbodies by DMF and assembling the plurality of metallic combustion turbine subcomponent greenbodies together to form a metallic greenbody assembly. The metallic greenbody assembly may be sintered to thereby form the metallic body.

Abstract: A bushing (30, 31) in a hole (26) through a ceramic matrix composite structure (20) with a flange (34, 38) on each end of the bushing (30, 31) extending beyond and around the hole and pressing against opposed surfaces (22,24) of the CMC structure (20) with a preload that resists buckling of the composite structure fibers and resists internal CMC fiber separation. A connecting element (40), such as a bolt or pin, passes through the bushing (30, 31) for engagement with a supporting element (50). The bushing (31) may be formed in place as a single piece of ceramic, and cured along with the CMC structure (20), or it may be formed as two ceramic or metal parts (32, 36) that are joined together and preloaded by threads (33). The connecting element (40) may be a pin, or it may be a bolt with a shaft threaded into one part (32) of the bushing and a head (42) that pushes the second flange (38) toward the first flange (34).

Abstract: An airfoil (101) is provided which includes a suction side and a pressure side joined along a trailing edge (106), wherein a trailing edge portion of the airfoil is configured to take a wavelike form along a radial direction of the airfoil, thereby improving the radial bending strength of the airfoil and reducing the magnitude of fluid flow wakes (128?) formed in a working fluid flowing over the airfoil.

Abstract: A ceramic matrix composite (CMC) airfoil assembled from a pressure side wall (42) and a suction side wall (52) joined by interlocking joints (18, 19) at the leading and trailing edges (22, 24) of the airfoil to produce a tapered thin trailing edge. The trailing edge (24) is thinner than a combined thicknesses of the airfoil walls (42, 52). One or both of the interlocking joints (18, 19) may be formed to allow only a single direction of assembly, as exemplified by a dovetail joint. Each joint (18, 19) includes keys (44F, 54F, 56F, 46F) on one side and respective keyways (44K, 54K, 56K, 46K) on the other side. Each keyway may have a ramp (45) that eliminates indents in the airfoil outer surface that would otherwise result from the joint.