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 hybrid metal-reinforced ceramic matrix composite (CMC) material component is provided having a body including a ceramic matrix composite material and a metal skeleton structure encompassing at least a portion of the body. A retaining structure carried by the metal skeleton structure is further included to induce a compressive force on the body to limit movement of the body and the metal skeleton structure relative to one another and enable the metal skeleton structure to carry a greater amount of an external load than the body.

Abstract: An interlocking modular airfoil for a turbine. The airfoil includes at least one support column extending from a lower plate and at least one first filament having at least one first side aperture that receives the support column in a first transverse direction. The airfoil also includes at least one second filament having at least one second side aperture that receives the support column in a second transverse direction, wherein the second filament includes a flange for covering the first side aperture. In addition, the airfoil includes a cooling channel extending through the support column, wherein the support column includes apertures for emitting a cooling fluid transmitted via the cooling channel for cooling the first and second filaments. Further, the airfoil includes an upper plate located on top of the first and second filaments for maintaining the first and second filaments under compression.

Abstract: A sealing band arrangement for a gas turbine including first and second adjoining rotor disks separated by a gap wherein the first rotor disk includes an aperture. The sealing band arrangement includes at least one seal strip segment located within the gap, wherein the seal strip segment includes a first mating surface. The sealing band arrangement further includes a block having a locking section located within the aperture to stop circumferential movement of the seal strip segment relative to the first and second disks. A tapered pin element extends through the seal strip segment and the block. The tapered pin element is friction welded to both the seal strip segment and the block to attach the block to the first mating surface of the seal strip segment.

Abstract: A sealing band arrangement for a gas turbine including first and second adjoining rotor disks separated by a gap wherein the first rotor disk includes an aperture. The sealing band arrangement includes at least one seal strip segment located within the gap, wherein the seal strip segment includes a first mating surface. The sealing band arrangement further includes a block having a locking section located within the aperture to stop circumferential movement of the seal strip segment relative to the first and second disks. A tapered pin element extends through the seal strip segment and the block. The tapered pin element is friction welded to both the seal strip segment and the block to attach the block to the first mating surface of the seal strip segment.

Abstract: A fatigue resistant turbine through bolt formed from a base material covered by a first surface modification and a second surface modification is disclosed. The first surface modification may be in contact with the base material and, in at least one embodiment, may be a low plasticity burnished layer that increases the residual compressive stresses on an outer surface of the turbine through bolt. The second surface modification may cover the first surface modification and, in at least one embodiment, may be a spinel oxide layer on the low plasticity burnished layer. The second surface modification may be positioned on the first surface modification or on the bare turbine through bolt contact surface without low plastiocity burnishing on the shaft of the turbine through bolt. The first and second surface modifications reduce the likelihood of fretting fatigue failures.

Abstract: A system (10) is provided for sealing a gap (12) between a transition exit frame (14) and a vane rail (18) at a turbine inlet (20). The system includes a seal (11) with a compliant seal member having a generally u-shaped profile to provide a sealing function in an axial direction. The compliant seal member includes a U-shaped inner sheet (28) securely pressed within a U-shaped outer sheet (26). The outer and inner sheets include spaced-apart segments (30, 32) in a lateral direction which are spaced-apart by misaligned slots (36, 38) to block passage of air there through. The system may also include wear resistant material (62) interposed between the seal and the vane rail. A lateral gap between adjacent exit frames may include a plurality of ribs defining valleys and tips, with crushable material disposed between the valleys and tips.

Abstract: A method for forming a textured bond coat surface (48) for a thermal barrier coating system (44) of a gas turbine component (34). The method includes selectively melting portions of a layer of alloy particles (16) with a patterned energy beam (20) to form successive layers of alloy material (16?, 16?) until a desired surface geometric feature (26) is achieved. The energy beam pattern may be indexed between layers to form a protruding undercut (28) in the geometric feature. The patterned energy beam may be formed by directing laser energy from a diode laser (30) through a cartridge filter (32). Particles of a flux material (18) may be melted along with the alloy particles to form a protective layer of slag (22) over the melted and cooling alloy material.

Abstract: A system (10) is provided for sealing a gap (12) between a transition exit frame (14) and a vane rail (18) at a turbine inlet (20). The system includes a seal (11) with a compliant seal member having a generally u-shaped profile to provide a sealing function in an axial direction. The compliant seal member includes a U-shaped inner sheet (28) securely pressed within a U-shaped outer sheet (26). The outer and inner sheets include spaced-apart segments (30, 32) in a lateral direction which are spaced-apart by misaligned slots (36, 38) to block passage of air there through. The system may also include wear resistant material (62) interposed between the seal and the vane rail. A lateral gap between adjacent exit frames may include a plurality of ribs defining valleys and tips, with crushable material disposed between the valleys and tips.

Abstract: A wear sensor (30, 50, 60) installed on a surface area (24) of a component (20, 21) subject to wear from an opposing surface (74, 75). The sensor has a proximal portion (32A, 52A, 62A) and a distal portion (32C, 52C, 62C) relative to a wear starting position (26). An electrical circuit (40) measures an electrical characteristic such as resistance of the sensor, which changes with progressive reduction of the sensor from the proximal portion to the distal portion during a widening reduction wear of the surface from the starting position. The measuring circuit quantifies the electrical changes to derive a wear depth based on a known geometry of the wear depth per wear width. In this manner, wear depth may be measured with a surface mounted sensor.

Abstract: A structure and method for instrumenting a component for monitoring wear in a coating. The method includes depositing a first thin layer of electrically insulating material, depositing a thin electrically conductive layer over the first electrically insulating layer, depositing a second thin layer of electrically insulating material over the electrically conductive layer. An overlying thickness of the coating material is deposited over the second thin layer of electrically insulating material. The thicknesses of the insulating and conducting layers is controlled to be small enough such that the overlying coating surface exposed to mechanical wear retains a desired degree of smoothness without the necessity for a separate planarization step.

Abstract: A structure and method for instrumenting a component for monitoring wear in a coating. The method includes depositing a first thin layer of electrically insulating material, depositing a thin electrically conductive layer over the first electrically insulating layer, depositing a second thin layer of electrically insulating material over the electrically conductive layer. An overlying thickness of the coating material is deposited over the second thin layer of electrically insulating material. The thicknesses of the insulating and conducting layers is controlled to be small enough such that the overlying coating surface exposed to mechanical wear retains a desired degree of smoothness without the necessity for a separate planarization step.

Abstract: A method of forming a wear resistant coating on a combustion turbine component includes melting an ingot including at least one metallic carbide to form a metallic liquid including at least one metallic carbide. The metallic liquid including at least one metallic carbide is atomized in an atmosphere to form a metallic powder including at least one metallic carbide. The metallic powder including at least one metallic carbide is milled to form a nanosized metallic powder including at least one metallic carbide. The nanosized metallic powder including at least one metallic carbide is thermally sprayed onto the combustion turbine component.

Abstract: A method is for forming a wear resistant coating on a workpiece. The method includes atomizing a metallic liquid including molybdenum in an atmosphere to form a crystalline metallic powder including molybdenum. The crystalline metallic powder is milled to form a nanocrystalline metallic powder including molybdenum. Moreover, the method includes thermal spraying the nanocrystalline metallic powder including molybdenum onto the workpiece.

Abstract: A wear sensor (30, 50, 60) installed on a surface area (24) of a component (20, 21) subject to wear from an opposing surface (74, 75). The sensor has a proximal portion (32A, 52A, 62A) and a distal portion (32C, 52C, 62C) relative to a wear starting position (26). An electrical circuit (40) measures an electrical characteristic such as resistance of the sensor, which changes with progressive reduction of the sensor from the proximal portion to the distal portion during a widening reduction wear of the surface from the starting position. The measuring circuit quantifies the electrical changes to derive a wear depth based on a known geometry of the wear depth per wear width. In this manner, wear depth may be measured with a surface mounted sensor.