Abstract: An abradable sealing element comprises a substrate and a sealing structure. The sealing structure comprises one or more wall structures extending from the substrate and defining at least one open cell which is filled with abradable material. The one or more wall structures are formed by additive-layer, powder-fed, laser-weld deposition onto the substrate. The one or more wall structures are formed from nickel-based superalloy and constitute from about 10% to about 50% of the total volume of the sealing structure.

Abstract: A method of forming a wall structure on a substrate comprises depositing, by additive-layer, powder-fed, laser-weld deposition apparatus, a plurality of material layers overlying one another on the substrate to form the wall structure. Each material layer of the plurality of material layers has (a) a layer thickness, measured in a direction locally perpendicular to a profile of the substrate, of no greater than about 350 ?m and (b) a layer width, measured in a direction locally parallel to the profile of the substrate, of no greater than about 1200 ?m.

Abstract: An abradable sealing element comprises a substrate and a sealing structure. The sealing structure comprises one or more wall structures extending from the substrate and defining at least one open cell which is filled with abradable material. The one or more wall structures are formed by additive-layer, powder-fed, laser-weld deposition onto the substrate. The one or more wall structures are formed from nickel-based superalloy and constitute from about 10% to about 50% of the total volume of the sealing structure.