Abstract: A process for forming a single crystal superalloy wave spring is provided. In one embodiment, the process may include machining a wave spring from a single crystal superalloy slab after optimizing its orientation using diffraction techniques so that the wave spring will exhibit optimal spring properties.

Abstract: A seal assembly is provided that includes a protective shroud to protect a sealing element from hazardous elements and/or a hazardous environment.

Abstract: A resilient, flexible, pressure-activated, high-temperature seal is adapted to be interposed between high and low pressure regions to provide sealing between opposing surfaces of adjacent relatively movable structures. The seal comprises at least one C-shaped sheet element. The C-shaped element design enables the seal to be pressure-activated to provide a radially outward biasing force, responsive to a seal-activating pressure differential acting across the seal thereby increasing resiliency. A centrally-located, resilient core structure provides load bearing and insulating properties. In an exemplary embodiment where at least two seal elements are used, each layer has a cutout slot pattern and the remaining strip material pattern. The slots provide flexibility to the seal, enabling the seal to be manually contoured to seal around corners and curves. The strip material of each layer covers the slots in each adjacent layer to minimize leakage through the slots.

Abstract: A high temperature sealing system is operative to seal an interface between adjacent hot structures and to minimize parasitic flow between such structures that move relative to one another in-plane or out-of-plane. The sealing system may be used to seal thrust-directing ramp structures of a reusable launch vehicle and includes a channel and a plurality of movable segmented sealing elements. Adjacent ramp structures include edge walls which extend within the channel. The sealing elements are positioned along the sides of the channel and are biased to engage with the inner surfaces of the ramp structures. The segmented sealing elements are movable to correspond to the contour of the thrust-directing ramp structures. The sealing system is operative to prevent high temperature thrust gases that flow along the ramp structures from infiltrating into the interior of the vehicle.

Abstract: A thermal barrier for extremely high temperature applications consists of a carbon fiber core and one or more layers of braided carbon fibers surrounding the core. The thermal barrier is preferably a large diameter ring, having a relatively small cross-section. The thermal barrier is particularly suited for use as part of a joint structure in solid rocket motor casings to protect low temperature elements such as the primary and secondary elastomeric O-ring seals therein from high temperature gases of the rocket motor. The thermal barrier exhibits adequate porosity to allow pressure to reach the radially outward disposed O-ring seals allowing them to seat and perform the primary sealing function. The thermal barrier is disposed in a cavity or groove in the casing joint, between the hot propulsion gases interior of the rocket motor and primary and secondary O-ring seals.