Abstract: Conventional electrochemical machining process requires fixed shaped tool cathodes, which makes retooling time consuming and expensive. Flexible tool cathodes include elastically deformable cathodes that can deform in two or three dimensions and can adapt to the contour of the workpiece while the workpiece is moving relative to the flexible tool cathode. That is, the flexible tool cathode can perform tracing. Certain flexible tool cathodes can be also used for special configurations such corners and edges. The flexible tool cathodes can be used to polish, finish, or shape the workpiece through electrochemical processes.

Abstract: A turbomachine seal assembly includes a plurality of sealing strips configured and disposed to inhibit a flow of fluid from passing through a channel defined by a first member and a second member. At least one of the plurality of sealing strips includes a paddle element that is configured and disposed to create a fluid recirculation zone at the channel. The fluid recirculation zone further inhibits the flow of fluid through the channel.

Abstract: A method of joining at least two components, a method of preventing erosion of a base component and a turbine blade is provided. The method of joining at least two components includes providing a laser cladding apparatus, aligning a first component and second component, and jointing the first and second components by laser cladding. The first component includes a first joining surface adjacent to a seconding joining surface of the second component. The first joining surface and the second joining surface are joined by laser cladding along a joining plane. A joining material from the laser cladding provides at least one joining layer between the first joining surface and the second joining surface. The first and second joining surfaces include a bevel angle. A method for rendering a component resistant to erosion and a turbine blade are also provided.

Abstract: According to various embodiment, a system includes an electrolytic cutting tool. The electrolytic cutting tool includes a first cathode configured to be positioned at a first gap away from a first side of a workpiece, a second cathode configured to be positioned at a second gap away from a second side of the workpiece. The first and second cathodes are positioned opposite from one another. The electrolytic cutting tool also includes a first electrolyte passage configured to flow a first electrolyte through the first gap between the first cathode and the workpiece, a second electrolyte passage configured to flow a second electrolyte through the second gap between the second cathode and the workpiece, and a power supply configured to flow current through the first gap and the second gap to cause electrolytic dissolution through the workpiece from both the first side and the second side.

Abstract: A brush seal, brush seal segment, and brush seal backplate for use in a rotary device are provided. In one embodiment, the invention provides a brush seal for a rotary device, the brush seal comprising: a plurality of brush seal segments, each segment including: an arcuate fence; an arcuate backplate circumferentially coextensive with the arcuate fence, the arcuate backplate including: a plurality of circumferentially-oriented cavities; a first dam along a first end of the arcuate backplate, the first dam substantially closing an end of at least one of the plurality of circumferentially-oriented cavities; and a second dam along a second end of the arcuate backplate, the second dam substantially closing an end of at least one of the plurality of circumferentially-oriented cavities; a plurality of brush bristles between the arcuate backplate and the arcuate fence; and a static member to which at least one of the plurality of brush seal segments is affixed.

Abstract: According to one aspect of the invention, a method for assembling a turbine includes placing a middle layer between a first and second outer member, wherein the middle layer includes a non-continuous layer of material and the first and second outer members each include a member of continuous material and welding a primary joint between the middle layer, first outer member and second outer member, the primary joint extending through the first outer member, the middle layer and at least a portion of the second outer member. The method also includes welding a secondary joint between the middle layer and first outer member, the secondary joint extending through the first outer member and at least a portion of the middle layer.

Abstract: Described herein a bucket for use in the last stage of a steam turbine engine. The bucket includes a titanium-based alloy having a leading edge wherein the leading edge includes titania having a plurality of pores and a top sealing layer filling the plurality of pores, the sealing layer selected from the group consisting of: chromium, cobalt, nickel, polyimide, polytetrafluoroethylene and polyester.

Abstract: A seal assembly for a turbomachine includes a plurality of compliant plate members attached to an interior surface of a stationary housing. The compliant plate members define a sealing ring between the stationary housing and a rotor. Each of the compliant plate members comprises at least one slot therein. The seal assembly further includes at least one arcuate static ring attached to the interior surface of the stationary housing and extending radially into the at least one slot in the compliant plate members. Each of the at least one static ring extends circumferentially through and between a plurality of the compliant plate members. Finally, the seal assembly includes a vibration damper disposed adjacent to or provided on the plurality of compliant plate members. The vibration damper is configured to dampen vibration of the plurality of compliant plate members.

Abstract: Systems and devices for sealing portions of a rotary machine are disclosed. In one embodiment, a seal assembly element includes: a head flange; an axial neck connected to the head flange, wherein the axial neck includes a mating flange extending circumferentially from a distal end of the seal assembly element, the mating flange configured to form a multidirectional seal with a recessed portion of a complementary seal assembly element; and a set of axial seal teeth connected to the axial neck.

Abstract: A seal is provided having a bristle pack with a first layer of bristles and a second layer of bristles. The bristle pack has at least one segment end. The first layer of bristles is configured to substantially surround the second layer of bristles, and at least one of the first layer of bristles has a first diameter. The second layer of bristles are located substantially in a center portion of the bristle pack, and at least one of the second layer of bristles has a second diameter. The first diameter is larger than the second diameter, and the first layer of bristles located near the at least one segment end are configured to protect the second layer of bristles located near the at least one segment end.

Abstract: A brush seal is provided having a brush housing having a back plate and a front plate, a first layer of bristles disposed adjacent to the back plate, where at least one of the first layer of bristles has a first diameter. A second layer of bristles are disposed adjacent to the first layer of bristles, and at least one of the second layer of bristles has a second diameter. A third layer of bristles are disposed adjacent to the second layer of bristles, and at least one of the third layer of bristles has a third diameter. The first diameter and the third diameter are larger than the second diameter.

Abstract: A brush seal and brush seal segment for use in a rotary device are provided. In one embodiment, the invention provides a brush seal comprising: a plurality of brush seal segments, each segment including: an arcuate fence; an arcuate backplate substantially circumferentially coextensive with the arcuate fence, the arcuate backplate including a first end and a second end; and a plurality of brush seal bristles between the arcuate backplate and the arcuate fence, the plurality of brush seal bristles being angled with respect to a radial axis of the arcuate backplate and at least one of the first end and the second end of the arcuate backplate; and a static member to which at least one of the plurality of brush seal segments is affixed.

Abstract: A method is provided for fabricating a seal ring. The method includes positioning a mount assembly adjacent to at least one of an inner diameter and an outer diameter of an annular seal ring, and securing the annular seal ring to the mounting assembly. The method also includes forming at least one of an admission side hook and a steam joint side hook in the annular seal ring.

Abstract: A brush seal for use between a rotating component and a stationary component in a turbomachine is disclosed. The brush seal according to embodiments of this invention include a set of bristles having a fixed end and a free end, wherein the fixed end is attached to the rotating component, and wherein the set of bristles are angled axially with respect to the rotating component.

Abstract: A device, apparatus, and method for abrasive electrochemical finishing of an arc flange leaf pack are presented. The device includes: a concave support block having holes to receive securing members; removable first and second end blocks configured to seat at opposite ends of the concave support block; removable first and second face plates attached to opposite sides of the concave support block via the securing members; and a region of space between the removable first and second face plates, the removable first and second end blocks, and the concave support block.

Abstract: A system includes an electrolytic deburring tool, which includes a first electrode configured to be positioned at a first gap away from a first edge of a workpiece, a second electrode configured to be positioned at a second gap away from a second edge of the workpiece, a first electrolyte supply configured to flow a first electrolyte through the first gap between the first electrode and the first edge of the workpiece, a second electrolyte supply configured to flow a second electrolyte through the second gap between the second electrode and the second edge of the workpiece, and a power supply configured to flow an alternating current through the first gap and the second gap to cause electrolytic dissolution through the workpiece from both the first edge and the second edge.

Abstract: A compliant plate seal arrangement manufacturing method is provided. A compliant plate seal manufacturing method includes assembling a plurality of t-shims and a plurality of spacer shims into a straight weld fixture, thereby forming a shim pack having a front and rear end and sides, welding the sides of the shim pack to a top plate, removing a portion of the weld fixture, removing the plurality of spacer shims, shaping the shim pack into a target diameter, and applying a radial flow plate to the leaf pack.

Abstract: A brush seal assembly for turbomachinery having a rotor can include a stationary seal component, a floating seal component coupled to the stationary seal component and circumferentially angled bristles arranged in a bristle pack, disposed in the floating seal component and extended axially with respect to the rotor.

Abstract: A method is provided for fabricating a seal ring. The method includes positioning a mount assembly adjacent to at least one of an inner diameter and an outer diameter of an annular seal ring, and securing the annular seal ring to the mounting assembly. The method also includes forming at least one of an admission side hook and a steam joint side hook in the annular seal ring.

Abstract: A cooling circuit for a drum rotor of a multi-stage steam turbine including tangential female dovetail slots in the drum rotor for tangential entry dovetailed buckets. Axial female dovetail slots are cut into drum rotor projections between stages of the tangential entry buckets for mounting axial inserts. The axial inserts may include axial and radial cooling passages allowing cooler external steam to cool the drum rotor flow through tangential cooling spaces between the tangential female dovetail slots and the tangential entry dovetailed buckets.