Seal systems for use in turbomachines and methods of fabricating the same

Patent metadata

Field	Value
Publication number	US-9598973-B2
Application number	US-201213687369-A
Country	US
Kind code	B2
Filing date	Nov 28, 2012
Priority date	Nov 28, 2012
Publication date	Mar 21, 2017
Grant date	Mar 21, 2017

Abstract

A seal system, for an apparatus that includes a rotatable portion with airfoils coupled thereto and a stationary portion with an inner surface, includes an abradable portion including at least one abradable layer of an abradable material formed over the inner surface. The seal system also includes an abrading portion disposed over at least a portion of a substrate of the airfoil. The abrading portion includes at least one abrading layer formed on at least a portion of the substrate and a plurality of abrasive particles embedded within the abrading layer. The plurality of abrasive particles includes at least one of substantially all of one of tantalum carbide (TaC), aluminum oxide (Al 2 O 3 ), and ziconia (ZrO 2 ), cubic boron nitride (cBN) and Al 2 O 3 in predetermined ratios, cBN, Al 2 O 3 and ZrO 2 in predetermined ratios, Al 2 O 3 and ZrO 2 fused together in predetermined ratios, and TaC and Al 2 O 3 in predetermined ratios.

First claim

What is claimed is:

1. A seal system for an apparatus that includes a rotatable portion and a stationary portion extending over at least a portion of the rotatable portion, the stationary portion includes an inner surface, the rotatable portion includes at least one airfoil assembly coupled thereto, wherein the at least one airfoil assembly includes a substrate, said seal system comprising:
an abradable portion comprising at least one abradable layer of an abradable material formed over at least a portion of the inner surface, wherein said abradable portion comprises an abradable surface face; and
an abrading portion disposed over at least a portion of the substrate, said abrading portion comprising:
at least one abrading layer formed on at least a portion of said substrate, wherein said at least one abrading layer defines an abrading layer surface; and
a plurality of abrasive particles embedded within said at least one abrading layer, wherein at least a portion of said plurality of abrasive particles extends beyond said abrading layer surface a first predetermined distance within a range between approximately 0% and 40% of an equivalent diameter of said plurality of abrasive particles, said plurality of abrasive particles are separated from each other with a spacing range between approximately 20μ and approximately 500μ, and said plurality of abrasive particles comprises at least one of:
substantially all of one of tantalum carbide (TaC), aluminum oxide (Al 2 O 3 ), and ziconia (ZrO 2 );
cubic boron nitride (cBN) and Al 2 O 3 in predetermined ratios;
cBN, Al 2 O 3 , and ZrO 2 in predetermined ratios;
Al 2 O 3 and ZrO 2 fused together in predetermined ratios; and
TaC and Al 2 O 3 in predetermined ratios,

wherein the abrading portion rubs against the abradable portion and defines a clearance gap between the abrading portion and the abradable portion, further defines a second predetermined distance between said abrading layer surface and said abradable surface face, and further wherein the clearance gap comprises a predetermined range of values, and further wherein said first predetermined distance and said second predetermined distance reduce a potential of contact between said abrading layer and said abradable shroud.

2. The seal system in accordance with claim 1 , wherein said plurality of abrasive particles further comprises:
particles sized in a range between approximately 50.8 microns (μ) and approximately 500μ.

3. The seal system in accordance with claim 1 , wherein said at least one abrading layer comprises at least one of at least one metallic layer and at least one ceramic layer.

4. The seal system in accordance with claim 1 , wherein said at least one abrading layer has a first hardness value and said plurality of abrasive particles has a second hardness value, wherein the second hardness value is greater than the first hardness value.

5. The seal system in accordance with claim 1 , wherein said plurality of abrasive particles further comprises at least some silicon carbide (SiC) particles comprising an external inert particle coating comprising at least one of Al 2 O 3 and mullite.

6. The seal system in accordance with claim 1 , wherein said at least one abrading layer comprises at least one of yttria-stabilized zirconia (YSZ), zirconia-toughened alumina, alumina-toughened zirconia, Al 2 O 3 , and hafnia (HfO 2 ).

7. The seal system in accordance with claim 1 , wherein said at least one abrading layer comprises at least one of:
a chromium-aluminum-yttrium alloy (MCrAlY), wherein M comprises at least one of nickel (Ni), cobalt (Co), and iron (Fe) in any combination thereof;
a chromium-aluminum alloy (MCrAlX), wherein M comprises at least one of nickel (Ni), cobalt (Co), and iron (Fe) in any combination thereof, and X comprises at least one of hafnium (Hf), Y, Si, and Ta in any combination thereof; and
an alloy comprising at least two of nickel (Ni), aluminum (Al), and platinum (Pt) in any combination thereof.

8. The seal system in accordance with claim 1 , wherein said at least abrading one layer has a thickness within a range between approximately 50.8μ, and approximately 500μ.

9. The seal system in accordance with claim 1 , wherein said abradable portion comprises at least one of:
dense vertically-cracked (DVC) yttria-stabilized zirconia (YSZ); and
dense vertically-cracked (DVC) dysprosia-stabilized zirconia (DySZ).

10. The seal system in accordance with claim 9 , wherein said DVC YSZ has a porosity value of less than 5%.

11. The seal system in accordance with claim 9 , wherein said DVC DySZ has a porosity value of less than 5%.

12. The seal system in accordance with claim 9 , wherein said abradable portion is formed with a thickness of at least approximately 500μ.

13. The seal system in accordance with claim 1 , wherein said clearance gap reduces a flow of a working fluid between said stationary portion and said rotatable portion.

14. A method of assembling a seal system for an apparatus, said method comprising:
providing a rotatable portion, wherein the rotatable portion includes at least one airfoil assembly coupled thereto, the at least one airfoil assembly includes a substrate;
extending a stationary portion over the at least a portion of the rotatable portion, wherein the stationary portion includes an inner surface;
forming an abradable portion comprising at least one layer of abradable material on at least a portion of the inner surface and further comprising an abradable surface face; and
forming an abrading portion comprising at least one matrix layer comprising an abrading layer surface, on at least a portion of the substrate, wherein the at least one matrix layer includes a plurality of abrasive particles embedded within the at least one matrix layer, wherein at least a portion of said plurality of abrasive particles extends beyond said abrading layer surface a first predetermined distance within a range between approximately 0% and 40% of an equivalent diameter of said plurality of abrasive particles, wherein the plurality of abrasive particles are separated from each other with a spacing range between approximately 20μ and approximately 500μ, wherein the plurality of abrasive particles includes at least one of:
substantially all of one of tantalum carbide (TaC), aluminum oxide (Al 2 O 3 ), and ziconia (ZrO 2 );
cubic boron nitride (cBN) and Al 2 O 3 in predetermined ratios;
cBN, Al 2 O 3 , and ZrO 2 in predetermined ratios;
Al 2 O 3 and ZrO 2 fused together in predetermined ratios; and
TaC and Al 2 O 3 in predetermined ratios,

wherein the abrading portion rubs against the abradable portion and defines a clearance gap between the abrading portion and the abradable portion, further defines a second predetermined distance between said abrading layer surface and said abradable surface face, and further wherein the clearance gap comprises a predetermined range of values, and further wherein said first predetermined distance and said second predetermined distance reduce a potential of contact between said abrading layer and said abradable shroud.

15. The method in accordance with claim 14 , wherein forming at least one layer of abradable material on the inner surface comprises spraying at least one of dense vertically-cracked (DVC) yttria-stabilized zirconia (YSZ) and dense vertically-cracked (DVC) dysprosia-stabilized zirconia (DySZ) on the inner surface, wherein the at least one layer of abradable material has a first hardness value, and the plurality of abrasive particles has a second hardness value, the second hardness value is greater than the first hard

Assignees

• Nuovo Pignone S R I
• Gen Electric

Inventors

• Ghasripoor Farshad
• Giovannetti Iacopo
• Giannozzi Massimo
• Anand Krishnamurthy
• Sheng Nuo
• Piche Nicole Barbara
• Leblanc Luc Stephane
• Hasz Wayne Charles
• Nelson Warren Arthur
• Thomas Paul Matthew
• Gray Dennis Michael

Classifications

• F05D2300/228

  Nitrides · CPC title

• F01D11/122 Primary

  with erodable or abradable material (blades having cutting or grinding tips F01D5/20) · CPC title

• F05D2300/506

  Hardness · CPC title

• F16J15/445

  with means for adjusting the clearance · CPC title

• F05D2230/31

  Layer deposition · CPC title