Abstract: A welding method and apparatus for welding workpieces together by conducting a laser beam welding process on a joint region that includes a weld seam defined by and between faying surfaces of the workpieces, and then conducting a hybrid laser arc welding process on the joint region. The laser beam welding process entails causing a first laser beam to travel along the joint region, penetrate the weld seam and form a weldment. The hybrid laser arc welding process remelts the weldment by simultaneously causing an electric arc and a second laser beam to overlap and travel along the joint region and form a weld pool in the weldment. On cooling, a weld joint is formed within the joint region and its weld seam.

Abstract: A system includes a gasification fuel injector. The gasification fuel injector includes a body having a tip portion, a first conduit extending through the body toward the tip portion, a second conduit extending through the body toward the tip portion, and a flow control device disposed in the first conduit upstream of the tip portion. The flow control device is configured to limit a first flow through the first conduit.

Abstract: A system and method for online monitoring of molten salt corrosion of a component of an apparatus is disclosed. First and second electrodes are electrically isolated from each other within the component and exposed to a corrosive operating environment of the apparatus. The first and second electrodes are electrically coupled such that when an electrical potential difference exists between the first and second electrodes an electrical current flows between the first electrode and the second electrode. The electrical potential difference between the first electrode and the second electrode is based at least in part on molten salt corrosion at the first electrode or the second electrode. At least one of the electrical potential difference or the electrical current flowing between the first electrode and second electrode is measured and analyzed such that a corrosion characteristic of the component can be predicted.

Abstract: A system for laser shock peening includes a laser positioned to direct a laser pulse at a first side of a work piece and a coupler on a second side of the work piece. The system further includes a Doppler shift detector positioned to measure a velocity of the coupler. A method for laser shock peening includes depositing an amount of energy from a laser pulse into a first side of a work piece and transmitting a pulse having a first frequency at a second side of the work piece. The method further includes receiving a reflected pulse having a second frequency from the second side of the work piece and determining the velocity of the work piece based on the difference between the first frequency and the second frequency.

Abstract: A corrosion sensor includes a plurality of conductive portions and at least one non-conductive portion between adjacent conductive portions, wherein the at least one non-conductive portion has a dimension less than approximately 500 microns. A method for manufacturing a corrosion sensor includes applying a non-conductive material to a substrate and applying a conductive material to discrete locations on the non-conductive material. The method further includes applying a brazing material around each discrete location of the conductive material.

Abstract: A method for manufacturing a corrosion sensor includes applying a first layer of non-conductive material to a substrate, writing a conductive material at discrete locations on the non-conductive material, and writing the conductive material at discrete locations on the previously written conductive material. The method further includes applying a second layer of non-conductive material over the conductive material and machining at least a portion of the second layer of non-conductive material to expose at least a portion of the conductive material.

Abstract: A method for manufacturing a corrosion sensor includes spraying a non-conductive material on a substrate and spraying a conductive material at discrete locations on the substrate or on the non-conductive material. The method further includes spraying the non-conductive material around the discrete locations of the conductive material.

Abstract: Embodiments disclosed herein provide hydrocarbon additives and methods of making and using the same. The additives are suitable for use in conjunction with gasifiers, furnaces, or other high-temperature vessels. The additives may be part of an input stream to a reaction vessel of a hydrocarbon gasifier. The additives may include materials that at least partially reduce the infiltration of slag into the refractory material.

Abstract: Embodiments disclosed herein provide hydrocarbon additives and methods of making and using the same. The additives are suitable for use in conjunction with gasifiers, furnaces, or other high-temperature vessels. The additives may be part of an input stream to a reaction vessel of a hydrocarbon gasifier. The additives may include materials that at least partially reduce the infiltration of slag into the refractory material.

Abstract: A system includes a syngas cooler configured to cool a syngas. The syngas cooler includes a first syngas cooler section configured to cool the syngas and a second syngas cooler section configured to cool the syngas and generate a first superheated steam with an enthalpy of less than approximately 3800 kJ/kg.

Abstract: A system includes a gasifier, which includes a reaction chamber configured to convert a feedstock into a synthetic gas, a quench chamber configured to cool the synthetic gas, a quench ring configured to provide a water flow to the quench chamber, and a quench ring protection system configured to protect the quench ring from the synthetic gas or a molten slag. The quench ring protection system includes a protective barrier disposed within an inner circumferential surface of the quench ring. The protective barrier substantially overlaps the inner circumferential surface in an axial direction along an axis of the quench ring.

Abstract: A fuel injector for injecting fuel into a gasifier includes a mating end including a nozzle portion and a first flange fixedly coupled to the mating end and having a first receiving hole there through and including a first diaphragm disposed therein. The injector also includes a fuel transmission nozzle displaced at least partially within the mating end and passing through the first receiving hole arranged and configured such that a secondary oxygen channel exists between the fuel transmission nozzle and the mating end, the fuel transmission nozzle being fixedly coupled to the first diaphragm and further including a fuel inlet for receiving fuel for introduction into the gasifier.

Abstract: A welding method and apparatus for welding workpieces together by conducting a laser beam welding process on a joint region that includes a weld seam defined by and between faying surfaces of the workpieces, and then conducting a hybrid laser arc welding process on the joint region. The laser beam welding process entails causing a first laser beam to travel along the joint region, penetrate the weld seam and form a weldment. The hybrid laser arc welding process remelts the weldment by simultaneously causing an electric arc and a second laser beam to overlap and travel along the joint region and form a weld pool in the weldment. On cooling, a weld joint is formed within the joint region and its weld seam.

Abstract: According to various embodiments, a system includes a gasifier that includes a shell made of a first material exposed to a gasification region inside the gasifier and a patterned anode layer coupled to the shell inside the gasifier. The patterned anode layer is made of a second material, and the patterned anode layer is configured to protect the shell from corrosion by condensing hot gas in the gasification region.

Abstract: According to various embodiments, a system includes a turbine engine component that includes a first material having a surface exposed to a fluid flow path and a sacrificial anode layer disposed on the surface. The sacrificial anode layer includes a second material that is electrochemically more active than the first material and the second material is configured to preferentially corrode to protect the first material from corrosion.

Abstract: A system for laser shock peening includes a laser positioned to direct a laser pulse at a first side of a work piece and a coupler on a second side of the work piece. The system further includes a Doppler shift detector positioned to measure a velocity of the coupler. A method for laser shock peening includes depositing an amount of energy from a laser pulse into a first side of a work piece and transmitting a pulse having a first frequency at a second side of the work piece. The method further includes receiving a reflected pulse having a second frequency from the second side of the work piece and determining the velocity of the work piece based on the difference between the first frequency and the second frequency.

Abstract: A method for fabricating a ceramic composite includes forming a first ceramic composite layer (CCL), positioning a form against the first CCL, positioning a second CCL against the form such that the form is at least partially circumscribed by the first CCL and the second CCL. The method also includes coupling the first CCL to the second CCL, such that at least a first passage extends in a first direction across at least a portion of the ceramic composite component and is defined at least partially by the first CCL and the second CCL in a location vacated by the first form.

Abstract: A system and method for online monitoring of molten salt corrosion of a component of an apparatus is disclosed. First and second electrodes are electrically isolated from each other within the component and exposed to a corrosive operating environment of the apparatus. The first and second electrodes are electrically coupled such that when an electrical potential difference exists between the first and second electrodes an electrical current flows between the first electrode and the second electrode. The electrical potential difference between the first electrode and the second electrode is based at least in part on molten salt corrosion at the first electrode or the second electrode. At least one of the electrical potential difference or the electrical current flowing between the first electrode and second electrode is measured and analyzed such that a corrosion characteristic of the component can be predicted.

Abstract: A system and method for online monitoring of corrosion of a pressure vessel is disclosed. First and second electrodes may be isolated from each other in a wall of the pressure vessel and exposed to a corrosive environment within the pressure vessel. Additionally, the first and second electrodes may be electrically coupled such that, when an electrical potential difference exists between the electrodes, an electrical current flows between the first electrode and the second electrode. The electrical potential difference and/or the electrical current flowing between the electrodes may then be measured and analyzed to determine when to perform a corrective action on the pressure vessel.

Abstract: A composite turbine blade and a method of manufacture thereof is disclosed. The composite turbine blade comprises a turbine blade portion comprising a first material and a first tip plate comprising a second material. The turbine blade portion has an exterior wall and an interior wall surrounding a hollow interior cavity, and a top surface extending from the exterior wall to the interior wall bounding an orifice that is fluidly connected to the hollow interior cavity. The first tip plate may be attached to the turbine blade along the top surface and extending from proximate the exterior wall of the turbine blade across the orifice to cover the orifice.