Abstract: A component for a gas turbine engine can be made via additive manufacturing. During the additive manufacturing process a powder can be used that comprises a superalloy material (12) and carbon nanostructures (14a, 14b). Components made using the powder can have preferred characteristics at certain locations through the use of the carbon nanostructure based additive manufacturing powder.

Abstract: A non-contact seal assembly for sealing a gap between relatively rotatable components in a gas turbine engine is presented. The non-contact seal assembly includes a primary seal having a radially movable seal shoe, a mid-plate, an aft secondary seal radially movable along with the seal shoe, a forward secondary seal and a U-shaped seal carrier for holding the components together using pins. The seal shoe includes a plurality of seal shoe segments. The aft secondary seal includes a plurality of aft secondary seal segments. Each aft secondary seal segment is attached to each seal shoe segment. Each aft secondary seal segment includes at least a notch at outer radial side to receive the pin for accommodating radial movement of the seal shoe segment.

Abstract: A non-contact seal assembly for sealing a gap between relatively rotatable components in a gas turbine engine is presented. The non-contact seal assembly includes a primary seal having a radially movable seal shoe, a mid-plate, an aft secondary seal radially movable along with the seal shoe, a forward secondary seal and a U-shaped seal carrier for holding the components together using pins. The seal shoe includes a plurality of seal shoe segments. The aft secondary seal includes a plurality of aft secondary seal segments. Each aft secondary seal segment is attached to each seal shoe segment. Each aft secondary seal segment includes at least a notch at outer radial side to receive the pin for accommodating radial movement of the seal shoe segment.

Abstract: A computer-implemented method for probabilistic quantification of probability of failure of a component, especially a gas turbine component, which during operation is subjected to cyclic stress, wherein the component is divided virtually in one or more domains. The method includes: providing or determining for at least one domain, a domain probability density function for crack initiation and providing or determining for the considered domains a domain probability density function for subsequent crack propagation induced failure. Determining for each considered domain a combined domain cumulative distribution function for failure or its probability density function is done by convoluting either both the considered domain probability density functions for crack initiation induced failure and the respective domain probability density function for subsequent crack propagation induced failure, or their integral function.

Abstract: A method for estimating life of a component includes obtaining fracture data corresponding to a component. The fracture data includes a first dataset corresponding to a threshold region where the crack in the component is dormant below a fatigue threshold. The method further includes determining initial estimates of parameters of a crack growth rate model and parameters of temperature models corresponding to the crack growth rate model based on the fracture data. The method also includes computing optimized parameters of temperature models corresponding to the crack growth rate model, and a scatter parameter via simulation of a joint optimization method using the initial estimates. The method includes determining a cumulative distribution function based on the optimized parameters and the scatter parameter and estimating life of the component based on the cumulative distribution function.

Abstract: A method for estimating life of a component includes obtaining fracture data corresponding to a component. The fracture data includes a first dataset corresponding to a threshold region where the crack in the component is dormant below a fatigue threshold. The method further includes determining initial estimates of parameters of a crack growth rate model and parameters of temperature models corresponding to the crack growth rate model based on the fracture data. The method also includes computing optimized parameters of temperature models corresponding to the crack growth rate model, and a scatter parameter via simulation of a joint optimization method using the initial estimates. The method includes determining a cumulative distribution function based on the optimized parameters and the scatter parameter and estimating life of the component based on the cumulative distribution function.

Abstract: A component for a gas turbine engine can be made via additive manufacturing. During the additive manufacturing process a powder can be used that comprises a superalloy material (12) and carbon nanostructures (14a, 14b). Components made using the powder can have preferred characteristics at certain locations through the use of the carbon nanostructure based additive manufacturing powder.

Abstract: Turbine engine (80) components, such as blades (92), vanes (104, 106), ring segment 110 abradable surfaces 120, or transitions (85), have vertically aligned engineered surface features (ESFs) (632, 634) and furcated engineered groove features (EGFs) (642, 652). A planform pattern of EGFs (642, 652) is cut into the outer surface of the component's thermal barrier coating (TBC). The EGF pattern includes a planform pattern of overlying vertices (644) respectively in vertical alignment with an underlying corresponding ESF (632, 634). At least three respective groove segments (642, 652, 642) within the EGF pattern (640) converge at each respective vertex (644) in a multifurcated pattern, so that crack-inducing stresses are attenuated in cascading fashion, as the stress (?A) is furcated (?B, ?C) at each successive vertex juncture.

Abstract: Turbine engine (80) components, such as blades (92), vanes (104, 106), ring segment 110 abradable surfaces 120, or transitions (85), have furcated engineered groove features (EGFs) (403, 404, 418, 509, 511, 512) that cut into the outer surface of the component's thermal barrier coating (TBC). In some embodiments, the EGF planform pattern defines adjoining outer hexagons (560, 640, 670, 690, 710). In some embodiments, the EGF pattern further defines within each outer hexagon (560, 640, 670, 690, 710) a planform pattern of adjoining inner polygons (570, 580, 590, 600, 610, 680, 682, 700, 702, 704, 705, 720). At least three respective groove segments (509, 511, 512) within the EGF pattern (506, 507, 508) converge at each respective outer hexagonal vertex (510, 564) or inner polygonal vertex (574, 564, 604, 614) in a multifurcated pattern, so that crack-inducing stresses are attenuated in cascading fashion, as the stress (?A) is furcated (?B, ?C) at each successive vertex juncture.

Abstract: A method for analyzing a three-dimensional stress concentrating feature of a component (60), such as a borehole (62), using a two-dimensional probabilistic technique. A circumferentially-dependent stress concentration profile around the stress concentrating feature is determined, and then a probability of failure of the component is calculated using a 2D probabilistic failure analysis of the stress concentration profile. The probabilistic failure analysis may include a Monte Carlo theta integration approach.

Abstract: A method for operating a machine component under stress. The method comprises determining a probability of failure PoF(N) of the component as a function of N cycles, selecting a time-based acceptable risk limit for the component and selecting an operational profile for the component, converting the time-based acceptable risk limit to a cycle-based acceptable risk limit using the operational profile, comparing the cycle-based acceptable risk limit with the PoF(N) values to determine an operational status of the component, comparing the cycle-based acceptable risk limit with the PoF(N) values, and operating the machine component responsive to results of the comparing step.

Abstract: A thermal boundary protection system including one or more carbon nanotubes for increased durability is disclosed. The thermal boundary protection system may include a bond coat applied on an outer surface of a base material, a thermal barrier coating applied on an outer surface of the bond coat, and a plurality of carbon nanotubes extending from the bond coat at least partially into the thermal barrier coating.

Abstract: A method for probabilistic fatigue life prediction using nondestructive testing data considering uncertainties from nondestructive examination (NDE) data and fatigue model parameters. The method utilizes uncertainty quantification models for detection, sizing, fatigue model parameters and inputs. A probability of detection model is developed based on a log-linear model coupling an actual flaw size with a nondestructive examination (NDE) reported size. A distribution of the actual flaw size is derived for both NDE data without flaw indications and NDE data with flaw indications by using probabilistic modeling and Bayes theorem. A turbine rotor example with real world NDE inspection data is presented to demonstrate the overall methodology.

Abstract: A method of brazing including melting a surface region (26) of a substrate (12, 14, 22) and contacting a braze material (10) with the melted surface region, the braze material including a plurality of braze fillers (16) and a plurality of carbon structures (18). The method further includes subjecting the braze material to an amount of energy effective to melt the braze fillers but not the carbon structures, and cooling the braze material to form a brazement (28, 32) including the carbon structures within at least a portion of the substrate. The brazement includes a gradient (30) of the carbon structures, wherein a concentration of the carbon structures increases in a direction away from an interior of the substrate.

Abstract: A method for selecting operating points of a gas turbine while taking into consideration at least one controlled variable, the operating points being defined at least by parameter combinations of manipulated variables, wherein the operating points are automatically selected on the basis of already known parameter combinations by using an interpolation method, the Kriging interpolation method being used as the interpolation method.

Abstract: A method for operating a machine component under stress. The method comprises determining a probability of failure PoF(N) of the component as a function of N cycles, selecting a time-based acceptable risk limit for the component and selecting an operational profile for the component, converting the time-based acceptable risk limit to a cycle-based acceptable risk limit using the operational profile, comparing the cycle-based acceptable risk limit with the PoF(N) values to determine an operational status of the component, comparing the cycle-based acceptable risk limit with the PoF(N) values, and operating the machine component responsive to results of the comparing step.

Abstract: A probabilistic estimation of fatigue crack life of a component is provided. A plurality of representations of the component is defined from material property scatter data and flaw-size scatter data, wherein each representation is defined by one possible material condition and flaw-size condition associated with the component. For each representation, a component location is selected and a determination is made whether said individual representation fails after a given number of cycles N, based on the calculation of a crack growth in the selected location. The crack growth is calculated on the basis of the material condition and the flaw-size condition in the selected location. Failure of the individual representation is determined if the crack growth is determined to be unstable. The sum total of the number of the representations that failed after N cycles is determined. A probability of failure of the component after N cycles is then determined.

Abstract: A method for producing a fuel lance for a burner, in particular for a gas turbine burner, has at least the following steps: creating a fuel lance body having a tip that has a cooling air duct, which opens into an exit opening extending around a longitudinal axis of the fuel lance body, and a nozzle face, which is arranged around the exit opening and has a plurality of fuel nozzles; determining a spatial distribution of a heat input, to which the nozzle face is subjected during operation when a fuel flowing out through the fuel nozzles is burnt; and applying a thermally insulating layer onto the nozzle face in accordance with the spatial distribution of the heat input. A fuel lance is produced with the method. A burner has such a fuel lance.

Abstract: A method for analyzing a three-dimensional stress concentrating feature of a component (60), such as a borehole (62), using a two-dimensional probabilistic technique. A circumferentially-dependent stress concentration profile around the stress concentrating feature is determined, and then a probability of failure of the component is calculated using a 2D probabilistic failure analysis of the stress concentration profile. The probabilistic failure analysis may include a Monte Carlo theta integration approach.

Abstract: A method for forming a coating matrix on a bore surface of a turbine disk wherein the coating matrix is applied at an interface between the disk and a turbine shaft. The coating matrix enhances thermal conductivity to increase heat transfer from the disk. The method includes providing a receiving surface on the bore surface. The receiving surface is then heated to melt the receiving surface. Next, at least one coating matrix layer is deposited on the receiving surface. The coating matrix layer includes a graphene layer. A pulsed laser system or a robot welding system may be used to melt the receiving section.