Wear-resistant inserts with lattice structure

Abstract

A wear resistant insert for a gas turbine engine, the wear resistant insert comprising: a base layer; a lattice layer connected to the base layer, wherein the lattice layer includes a series of walls defining a plurality of cells; and a sheet layer connected to the lattice layer on a side of the lattice layer opposite the base layer, wherein the sheet layer is curved and includes a concave direction facing away from the base layer, wherein the lattice layer and the sheet layer are integrally formed together and are a unitary piece of material.

Description

Technical Field

[0001] The present disclosure relates to a gas turbine engine. In particular, the present disclosure relates to a wear-resistant insert for use in a gas turbine engine. Background Art

[0002] A gas turbine engine generally comprises a turbine and a rotor assembly. Gas turbine engines, such as turbofan engines, can be used for aircraft propulsion. In the case of a turbofan engine, the rotor assembly can be configured as a fan assembly.

[0003] In gas turbine engines, wear-resistant materials can be provided to enhance the sealing interface between stationary and rotating components. Existing processes for constructing wear-resistant materials involve brazing layers together to form the wear-resistant material. This process requires a minimum wall thickness of the material and the addition of brazed joints, which can significantly increase the thickness of the material layers. The inventors of the present disclosure have discovered that these aspects of existing wear-resistant materials can lead to undesirable wear on rotating seal components and generate significant amounts of heat energy due to the large thickness of the wear-resistant material and brazed joints. Therefore, the inventors of the present disclosure have discovered that improvements to these wear-resistant materials would be beneficial. BRIEF DESCRIPTION OF THE DRAWINGS

[0004] A full and effective disclosure of the present disclosure, including the best mode thereof, to one of ordinary skill in the art is set forth in the specification with reference to the accompanying drawings, in which:

[0005] Figure 1 is a cross-sectional view of a gas turbine engine according to an exemplary aspect of the present disclosure.

[0006] Figure 2 is a perspective view of a wear insert according to an exemplary aspect of the present disclosure.

[0007] Figure 3 According to another exemplary aspect of the present disclosure Figure 2 3-3 is a cross-sectional view of the wear resistant insert and shows the base layer, the grid layer and the intermediate layer and the layer.

[0008] Figure 4 is a cross-sectional view of a wear resistant insert according to yet another exemplary aspect of the present disclosure and illustrating a base layer, a plurality of cell layers, a plurality of intermediate plies, and a ply layer.

[0009] Figure 5 is a cross-sectional view of a wear insert according to yet another exemplary aspect of the present disclosure and showing an intermediate ply and plies having dimples.

[0010] Figure 6 is a cross-sectional view of a wear resistant insert having a filler material according to yet another exemplary aspect of the present disclosure.

[0011] Figure 7 is a simplified illustration of variously shaped cells of a cell layer of a wear resistant insert according to yet another exemplary aspect of the present disclosure.

[0012] Figure 8 is a diagram showing a release gap in an intermediate sheet according to yet another exemplary aspect of the present disclosure.

[0013] Figure 9 is a flow chart of a method of manufacturing a wear resistant insert according to yet another exemplary aspect of the present disclosure. DETAILED DESCRIPTION

[0014] Reference will now be made in detail to the present embodiments of the present disclosure, one or more examples of which are illustrated in the accompanying drawings. The detailed description uses numerical and letter designations to refer to features in the drawings. Like or similar designations in the drawings and the description have been used to refer to like or similar parts of the disclosure.

[0015] The word "exemplary" is used herein to mean "serving as an example, instance, or illustration." Any implementation described herein as "exemplary" is not necessarily to be construed as preferred or advantageous over other implementations. Furthermore, all embodiments described herein are to be considered exemplary unless expressly stated otherwise.

[0016] As used herein, the terms “first,” “second,” and “third” may be used interchangeably to distinguish one component from another and are not intended to indicate the position or importance of each component.

[0017] The terms "fore" and "aft" refer to relative positions within a gas turbine engine or vehicle and refer to the normal operating attitude of the gas turbine engine or vehicle. For example, for a gas turbine engine, the front position refers to the position closer to the engine inlet, while the aft position refers to the position closer to the engine nozzle or exhaust.

[0018] The terms "upstream" and "downstream" refer to relative directions of fluid flow in a fluid path. For example, "upstream" refers to the direction from which the fluid is flowing, and "downstream" refers to the direction to which the fluid is flowing.

[0019] The terms “coupled,” “fixed,” “attached,” and the like refer to both direct coupling, fixing, or attachment, as well as indirect coupling, fixing, or attachment through one or more intermediate components or features, unless otherwise indicated herein.

[0020] The singular forms "a," "an," and "the" include plural references unless the context clearly dictates otherwise.

[0021] Approximate language used throughout the specification and claims is applied to modify any quantitative expression that can be allowed to change without resulting in a change in the basic function to which it is related. Therefore, the values ​​modified by one or more terms such as "about", "approximately" and "substantially" are not limited to the specified precise values. In at least some cases, approximate language can correspond to the accuracy of the instrument used to measure the value, or the accuracy of the method or machine used to construct or manufacture the component and / or system. For example, approximate language can refer to within a margin of 1%, 2%, 4%, 10%, 15%, 20%. These approximate margins can be applied to a single value, any endpoint or two endpoints of a defined numerical range, and / or the margin of the range between the endpoints.

[0022] Here and throughout the specification and claims, range limitations are combined and interchanged, and unless context or language indicates otherwise, such ranges are identified and include all sub-ranges contained therein. For example, all ranges disclosed herein are inclusive of the endpoints, and the endpoints are independently combinable with each other.

[0023] The terms "low" and "high," or their respective comparatives (e.g., lower, if applicable), when used with reference to a compressor, turbine, shaft or spool component, etc., each refer to relative speeds within the engine, unless otherwise specified. For example, a "low turbine" or "low-speed turbine" defines a component that is configured to operate at a lower speed (e.g., maximum allowable speed) than a "high turbine" or "high-speed turbine" at the engine.

[0024] The term “turbomachine” or “turbomachine” refers to a machine that includes one or more compressors, a heat generating section (eg, a combustion section), and one or more turbines that together produce a torque output.

[0025] The term "gas turbine engine" refers to an engine having a turbine as all or part of its power source. Example gas turbine engines include turbofan engines, turboprop engines, turbojet engines, turboshaft engines, and the like.

[0026] The term "combustion section" refers to any heat addition system for a turbomachine. For example, the term combustion section may refer to a section that includes one or more of a deflagration combustion assembly, a rotating detonation combustion assembly, a pulse detonation combustion assembly, or other suitable heat addition assembly. In certain exemplary embodiments, the combustion section may include an annular combustor, a can combustor, a can-annular combustor, a trapped vortex combustor (TVC), or other suitable combustion systems, or combinations thereof.

[0027] The term "layer-by-layer additive manufacturing" generally refers to a manufacturing process in which successive layers of material are provided on top of each other to "build up" a three-dimensional part layer by layer. The successive layers are typically fused together to form a unitary part that may have a variety of integral sub-components. Although additive manufacturing techniques are described herein as being capable of making complex objects by building up the object point by point, layer by layer, and typically in a vertical direction, other manufacturing methods are possible and within the scope of the present subject matter. For example, although the discussion herein refers to adding material to form successive layers, those skilled in the art will understand that the methods and structures disclosed herein can be practiced with any additive manufacturing technique or manufacturing technology. For example, embodiments of the present disclosure may use a layer additive process, a layer subtractive process, or a hybrid process.

[0028] Suitable additive manufacturing techniques according to the present disclosure include, for example, fused deposition modeling (FDM), selective laser sintering (SLS), 3D printing (e.g., by inkjet, laser jetting, and binder jetting), stereolithography (SLA), direct selective laser sintering (DSLS), electron beam sintering (EBS), electron beam melting (EBM), laser engineered net shape (LENS), laser net shape manufacturing (LNSM), direct metal deposition (DMD), digital light processing (DLP), direct selective laser melting (DSLM), selective laser melting (SLM), direct metal laser melting (DMLM), and other known processes.

[0029] The additive manufacturing processes described herein can be used to form components using any suitable material. Furthermore, it should be understood that a variety of materials and methods for combining these materials can be used and are considered within the scope of this disclosure. Furthermore, the additive manufacturing processes disclosed herein can allow a single component to be formed from multiple materials. Thus, the components described herein can be formed from any suitable mixture of materials.

[0030] The additive manufacturing methods described above enable the components described herein to have more intricate shapes and contours. For example, such components can include thin additively manufactured layers and unique fluid channels and manifolds with integrated mounting features. Furthermore, additive manufacturing processes enable the fabrication of a single component from different materials, allowing different portions of the component to exhibit different performance characteristics. The continuous, additive nature of the manufacturing process enables the construction of these novel features. As a result, the components described herein can exhibit improved functionality and reliability.

[0031] The present disclosure relates to wear-resistant inserts for rotating seal assemblies (e.g., labyrinth seals) in gas turbine engines. In certain designs, wear-resistant materials with exposed honeycomb cells can be incorporated into the inserts to provide a roughened surface resulting from the exposed honeycomb cells. Honeycomb cells fully exposed to the ambient air can generate significant stator drag and windage (e.g., windage within the rotor cavity) during engine operation.

[0032] Aspects of the present disclosure provide a wear-resistant insert having a thin cylindrical foil at the inner diameter surface of a honeycomb cell. Additional cylindrical foils can be integrated at various intervals along the honeycomb height for structural reinforcement to achieve larger honeycomb cell sizes, which can reduce airflow through the insert having friction grooves formed therein. The thin cylindrical foil provides a smooth airflow surface, which can reduce wind resistance and improve leakage. Additionally or alternatively, dimples can be used in the cylindrical foil at each honeycomb cell to provide thermal strain relief, aerodynamic benefits, etc. Additionally or alternatively, gaps can be formed in the cylindrical foil to provide further strain relief.

[0033] Referring now to the drawings, in which like numerals represent like elements throughout, Figure 1 is a schematic cross-sectional view of a propulsion system 10 according to an exemplary embodiment of the present disclosure. More specifically, Figure 1 In an embodiment of the present invention, the propulsion system 10 includes a gas turbine engine, referred to herein as a "turbofan engine 12." In one example, the turbofan engine 12 may be a high-bypass turbofan jet engine. Figure 1 As shown, the turbofan engine 12 defines an axial direction A (extending parallel to a longitudinal centerline 14 provided for reference) and a radial direction R. Generally, the turbofan engine 12 includes a fan section 16 and a turbine 18 disposed downstream of the fan section 16 .

[0034] The exemplary turbomachine 18 shown generally includes a substantially tubular outer casing 20 defining an annular inlet 22. Outer casing 20 encloses, in series flow order / relationship: a compressor section, which includes a supercharger or low-pressure compressor 24 ("LP compressor 24") and a high-pressure compressor 26 ("HP compressor 26"); a combustion section 28; a turbine section, which includes a high-pressure turbine 30 ("HP turbine 30") and a low-pressure turbine 32 ("LP turbine 32"); and combustion section 28. A high-pressure shaft or spool 34 ("HP spool 34") drivingly connects HP turbine 30 to HP compressor 26. A low-pressure shaft or spool 36 ("LP spool 36") drivingly connects LP turbine 32 to LP compressor 24.

[0035] For the depicted embodiment, fan section 16 includes a variable pitch fan 38 having a plurality of fan blades 40 coupled to a disk 42 in a spaced-apart manner. As shown, fan blades 40 generally extend outwardly from disk 42 in a radial direction R. Each fan blade 40 can be rotated relative to disk 42 about a pitch axis P by being operably coupled to a suitable actuation member 44 that is configured to collectively, e.g., in unison, change the pitch of fan blades 40. Fan blades 40, disk 42, and actuation members 44 can be rotated together about longitudinal centerline 14 via LP spool 36 across a power gearbox 46. Power gearbox 46 includes a plurality of gears for reducing the rotational speed of LP spool 36 to a more efficient fan speed.

[0036] Still refer to Figure 1 In an exemplary embodiment of the present invention, the disk 42 is covered by a rotatable forward hub 48 having an aerodynamic profile to facilitate airflow through the plurality of fan blades 40. In addition, the fan section 16 includes an annular fan casing or outer nacelle 50 that circumferentially surrounds the variable pitch fan 38 and / or at least a portion of the turbine 18. It should be understood that in some embodiments, the nacelle 50 is configured to be supported relative to the turbine 18 by a plurality of circumferentially spaced outlet guide vanes 52. Furthermore, a downstream section 54 of the nacelle 50 extends over an outer portion of the turbine 18 to define a bypass airflow passage 56 therebetween.

[0037] During operation of turbofan engine 12, a volume of air 58 enters turbofan engine 12 through nacelle 50 and / or associated inlet 60 of fan section 16. As volume of air 58 passes through fan blades 40, a first portion of air 58, as indicated by arrow 62, is directed or channeled into bypass airflow passage 56, and a second portion of air 58, as indicated by arrow 64, is directed or channeled into LP compressor 24. The ratio between first portion 62 of air and second portion 64 of air is generally referred to as a bypass ratio. The pressure of second portion 64 of air is then increased as it is directed through high pressure (HP) compressor 26 and into combustion section 28, where it is mixed with fuel and combusted to provide combustion gases 66. Combustion gases 66 are then directed through HP turbine 30 and LP turbine 32, where a portion of the heat and / or kinetic energy from combustion gases 66 is extracted.

[0038] The combustion gases 66 are then directed through the combustion section 28 of the turbine 18 to provide propulsive thrust. Simultaneously, the pressure of the first portion of air 62 is significantly increased as the first portion of air 62 is directed through the bypass airflow passage 56 before being discharged from the fan nozzle exhaust section 68 of the turbofan engine 12, also providing propulsive thrust.

[0039] However, it should be understood that Figure 1 The turbofan engine 12 depicted in FIG. 1 is merely an example, and in other exemplary embodiments, aspects of the present disclosure may additionally or alternatively be applied to any other suitable gas turbine engine. For example, in other exemplary embodiments, the turbofan engine 12 may alternatively be any other suitable aviation gas turbine engine, such as a turbojet engine, a turboshaft engine, a turboprop engine, etc. Additionally, in other exemplary embodiments, the turbofan engine 12 may include any other suitable number and / or configuration of shafts, spools, compressors, turbines, etc.; may be configured as a direct drive engine (e.g., without including a power gearbox 46); may be a fixed pitch fan; etc.

[0040] Now refer to Figure 2 , Figure 2 is a perspective view of an insert 70 according to an exemplary embodiment of the present disclosure.

[0041] Insert 70 is a component of the propulsion system 10 (see e.g. Figure 1 ) is a wear resistant insert. In other words, the insert 70 is operable with a component of the propulsion system 10. In certain exemplary embodiments, the insert 70 may form part of a wear resistant seal configured to engage with the LP turbine 32 for a turbofan engine (see, e.g., Figure 1 In another exemplary embodiment, the insert 70 may be configured to engage a labyrinth seal or a tip shroud seal of a turbofan engine 12 (see, e.g., Figure 1 ) forms a sealing interface with a labyrinth seal or a tip shroud seal of a turbofan engine 12. In yet another exemplary embodiment, the insert 70 may be configured to interface with an LP turbine 32 (see, e.g., Figure 1 )'s labyrinth seal or tip shroud seal is wear-resistantly engaged.

[0042] Insert 70 includes a base layer 72, a grid layer 74 (having a first layer 76, a middle layer 78, and a second layer 80), and layers 82. Insert 70 is used with propulsion system 10 by installing or positioning a plurality of inserts 70 around the circumference of a rotating element of propulsion system 10 (e.g., any of the rotor blades / fan blades 40 of LP compressor 24, HP compressor 26, HP turbine 30, LP turbine 32, or fan 38). In this manner, the plurality of inserts 70 form an annular wear-resistant seal.

[0043] In this example, base layer 72 is a solid block of material, such as metal. Base layer 72 is connected to lattice layer 74. In some exemplary embodiments, lattice layer 74 can be attached or mounted to the base layer via mechanical or chemical attachment. In other exemplary embodiments, base layer 72 and lattice layer 74 can be integrally formed together as a single, unitary material via layer-by-layer additive manufacturing.

[0044] In this example, the lattice layer 74 includes a first layer 76, an intermediate layer 78, and a second layer 80. As will be explained in more detail below, the first layer 76 and the second layer 80 are cellular material layers and include a series of walls defining a plurality of cells. In certain exemplary embodiments, the first layer 76 and the second layer 80 may include a three-dimensional lattice structure or a honeycomb cell structure.

[0045] The intermediate layer 78 is a thin layer of solid material disposed between the base layer 72 and the layer 82. In this example, the intermediate layer 78 separates the cells of the lattice layer 74 into a first layer 76 and a second layer 80.

[0046] Middle sheet 78 is curved along a first direction 84 and flat along a second direction 86, which is perpendicular to first direction 84. In certain exemplary embodiments, middle sheet 78 may be integrally formed with first layer 76 and second layer 80 by layer-by-layer additive manufacturing.

[0047] The lamella 82 is another thin piece of solid material or foil connected to the lattice layer 74 along the second layer 80. In this example, the lamella 82 is curved along a first direction 84 and is flat along a second direction 86. The lamella 82 includes a concave direction facing away from the base layer 72. In addition, for the illustrated embodiment, the exposed surface of the lamella 82 is smooth (e.g., uniform and non-porous). When multiple inserts 70 are placed together to form a ring of inserts 70 with the first direction 84 being the circumferential direction, the multiple lamellas 82 of the multiple inserts 70 form a thin cylindrical foil along the inner diameter of the ring of inserts 70. The lamella 82 is connected to the lattice layer 74 on the side opposite the base layer 72. In certain exemplary embodiments, the exposed surface of the lamella 82 defines the flow path surface wall of the propulsion system 10.

[0048] In certain exemplary embodiments, two or more of the base layer 72 , first layer 76 , intermediate sheet layer 78 , second layer 80 , and sheet layer 82 may be integrally formed together as a single, unitary piece of material via layer-by-layer additive manufacturing.

[0049] In other exemplary embodiments, the material of insert 70 may include a nickel alloy having a temperature threshold greater than 700 degrees Fahrenheit (e.g., a melting point of up to 2,500°F). For example, as used herein, the term "temperature threshold" may indicate a temperature limit above which the material of insert 70 will not be durable for the expected engine life. Failure to meet the required durability may be due to a variety of reasons, such as oxidation or corrosion of the material that degrades at higher temperatures. In at least some exemplary aspects, the material of insert 70 (and / or one or more of base layer 72, first layer 76, intermediate sheet 78, second layer 80, and sheet 82) may include a nickel-chromium-aluminum-iron alloy or a nickel-molybdenum alloy.

[0050] During operation, in the event of abrasive wear (e.g., when a rotating seal component of the propulsion system 10 contacts and wears a portion of the insert 70), a portion of the sheet 82 is worn away from the insert 70. In this event, the remaining portion of the insert 70 that is not abrading remains intact, and the smooth sheet 82 remains on the portion of the insert 70 that is not abrading.

[0051] With smooth sheet 82 largely intact, resistance to air flowing through insert 70 is lower, allowing the air to spin faster. As the air spins faster, the corresponding rotating element (e.g., the rotor of LP compressor 24, HP compressor 26, HP turbine 30, or LP turbine 32) generates less heat and less windage, resulting in fewer parasitic losses on the rotor and air. In other words, the unrubbed, smooth surface of sheet 82 reduces windage in the area surrounding insert 70. For example, reducing windage in the area surrounding insert 70 can increase cavity temperature and help reduce parasitic pressure and temperature losses in propulsion system 10.

[0052] Now refer to Figure 3 , Figure 3 According to an exemplary embodiment of the present disclosure Figure 2 3-3 is a cross-sectional view of the insert 70.

[0053] Here, the first layer 76 and the second layer 80 are shown as including walls 88 and joints 96. The walls 88 are Figure 3 8 and is a thin planar sheet of solid material such as metal. Each of the walls 88 includes a thickness 90. The thickness 90 may refer to the maximum thickness of the corresponding wall 88.

[0054] In certain exemplary embodiments, the thickness 90 of each wall 88 of the series of walls 88 is less than or equal to 10.0 thousandths of an inch; e.g., less than or equal to 5.0 thousandths of an inch (0.127 mm); e.g., less than or equal to 3.0 thousandths of an inch (0.076 mm); e.g., at least about 0.2 thousandths of an inch.

[0055] In certain exemplary embodiments, the thickness 92 of the intermediate layer 78 and the thickness 94 of the layer 82 are less than or equal to 10.0 thousandths of an inch; for example, less than or equal to 5.0 thousandths of an inch (0.127 mm); for example, less than or equal to 3.0 thousandths of an inch (0.076 mm); for example, at least about 0.2 thousandths of an inch. Thicknesses 92, 94 can each refer to the maximum thickness of the respective layer 78, 82.

[0056] like Figure 3 As shown, joint 96 is formed at the intersection between middle sheet 78 and wall 88. In this example, middle sheet 78 and wall 88 are formed integrally via layer-by-layer additive manufacturing. Joint 96 each defines a thickness 98. The thickness 98 of joint 96 can refer to the maximum thickness in the transverse direction relative to the extension between sheet 78, 82 and the joined wall 88. In certain exemplary embodiments, the thickness 98 of joint 96 is less than or equal to 10.0 thousandths of an inch (0.254 mm; for example, less than or equal to 7.0 thousandths of an inch (0.178 mm); for example, less than or equal to 5.0 thousandths of an inch (0.127 mm); for example, less than or equal to 3.0 thousandths of an inch (0.076 mm); for example, at least about 0.2 thousandths of an inch (0.051 mm)). In other words, the maximum thickness of one of the joints 96 is less than or equal to 10.0 thousandths of an inch (0.254 mm; e.g., less than or equal to 7.0 thousandths of an inch (0.178 mm); e.g., less than or equal to 5.0 thousandths of an inch (0.127 mm); e.g., less than or equal to 3.0 thousandths of an inch (0.076 mm); e.g., at least about 0.2 thousandths of an inch (0.051 mm)).

[0057] In gas turbine engines, some processes for constructing unitized wear parts involve brazing layers and units together to form the wear part. Such processes require minimum cell wall thickness and the addition of brazed joints, which can add, for example, 20 mm of material to the cell walls. These aspects of the wear part can lead to undesirable wear on the seal teeth and generate significant heat energy due to the large thickness of the wear wall and brazed joints. Furthermore, the additional brazing material adds undesirable size and mass to the wear material.

[0058] Here, because the lattice layer 74 and the sheet layer 82 are integrally formed via layer-by-layer additive manufacturing, thick brazing joints are not required and the thicknesses 90, 92, 94, and 98 can be reduced to, for example, three thousandths of an inch or less. In this way, the weight of the insert 70 can be reduced and the need for additional brazing processes can be eliminated compared to the above-described construction methods.

[0059] Furthermore, the addition of the intermediate sheet layer 78 provides structural reinforcement to the lattice layer 74, thereby making the cell size of the honeycomb structure of the lattice layer 74 larger and potentially reducing airflow when friction grooves are formed due to friction events.

[0060] Now refer to Figure 4 , Figure 4 is a cross-sectional view of an insert 70' according to an exemplary embodiment of the present disclosure. The insert 70' may be Figure 3 The exemplary insert 70 is constructed in a similar manner. However, as Figure 4 As shown, the insert 70' includes a first intermediate sheet 78A and a second intermediate sheet 78B.

[0061] In this example, the lattice layer 74 includes a first cell 100. The first cell 100 is a closed portion of the lattice layer 74. The first cell 100 is defined at the bottom by the base layer 72, at the sides by the walls 88, and at the top by the first intermediate sheet 78A (e.g., Figure 4 , bottom, side, and top directions are depicted as downward, side-to-side, and upward.) The first cell 100 defines a first depth 102 extending from the base layer 72 to the first intermediate sheet 78A.

[0062] In this example, the lattice layer 74 also includes a second cell 104. The second cell 104 is a closed portion of the lattice layer 74. The second lattice 104 is defined at the bottom by the first intermediate sheet 78A, at the sides by the walls 88, and at the top by the second intermediate sheet 78B (e.g., Figure 4 , bottom, side, and top directions are depicted as downward, side-to-side, and upward). Second cell 104 defines a second depth 106 extending from first intermediate sheet 78A to second intermediate sheet 78B. In some exemplary embodiments, second depth 106 can be less than or equal to first depth 102.

[0063] In this example, the lattice layer 74 also includes a third cell 108. The third cell 108 is a closed portion of the lattice layer 74. The third cell 108 is defined at the bottom by the second intermediate sheet 78B, at the sides by the walls 88, and at the top by the sheet 82 (e.g., as shown in FIG. Figure 4(As shown, the bottom, side, and top directions are depicted as downward, side-to-side, and upward). The third unit 108 defines a third depth 110 extending from the second intermediate sheet 78B to the sheet 82. In some exemplary embodiments, the third depth 110 can be less than or equal to the second depth 106. Figure 4 In the example shown, the third depth 110 is less than the second depth 106 , and the second depth 106 is less than the first depth 102 .

[0064] During operation of the propulsion system 10, the rotating sealing elements (eg, teeth of a labyrinth seal, also known as rotating teeth) will be positioned upward relative to the insert 70', as shown in FIG. Figure 4 In the event that the insert 70' rubs against the rotating seal element, the rotating seal element will contact the sheet layer 82 and dig into a portion of the grid layer 74, potentially penetrating downwardly into the third cell 108, the second cell 104, and / or the first cell 100. During a friction event (e.g., the labyrinth teeth digging into the insert 70'), air continues to flow through the labyrinth teeth and insert 70' by bending downwardly into the grid layer 74 and around the labyrinth teeth.

[0065] Because the third cell 108 has a relatively small depth, there is not as much room for the air to drop down and back around the labyrinth teeth as compared to an example without a middle sheet. As the air passes down through the third cell 108, the air has a higher base below it to drop down into the third cell 108 and pass under the labyrinth teeth.

[0066] In this manner, insert 70' having multiple intermediate sheets (e.g., first intermediate sheet 78A and second intermediate sheet 78B) at different depths (e.g., first, second, and third depths 102, 106, and 110) provides more restriction to air passing through the labyrinth teeth and results in less airflow through the labyrinth teeth, thereby reducing overall leakage through insert 70' when friction occurs.

[0067] Now refer to Figure 5 , Figure 5 is a cross-sectional view of an insert 70' according to another exemplary embodiment of the present disclosure. The insert 70' may be Figure 4 The exemplary insert 70 is constructed in a similar manner. However, for Figure 5 In the embodiment of FIG. 7 , the insert 70 ′ includes a plurality of dimples 112 in each of the first intermediate sheet 78A, the second intermediate sheet 78B, and the sheet 82 .

[0068] The dimples 112 are depressions or domes (e.g., recessed or raised relative to the base layer 72). Figure 5As shown, each of first unit 100, second unit 104, and third unit 108 includes dimples 112 formed in corresponding portions of first intermediate sheet 78A, second intermediate sheet 78B, and sheet 82. In certain exemplary embodiments, a single one (e.g., sheet 82) or any combination of first intermediate sheet 78A, second intermediate sheet 78B, and sheet 82 may include dimples 112.

[0069] In this example, each dimple 112 in the plurality of dimples 112 is aligned with a cell of one of the first cell 100, the second cell 104, and the third cell 108. More specifically, in at least some exemplary aspects, a center or vertex of the dimple is aligned with a center or center point of one of the first cell 100, the second cell 104, and the third cell 108.

[0070] In certain exemplary embodiments, the dimples 112 may be oriented such that the dimples 112 are concave away from the base layer 72 and convex toward the base layer (e.g., as shown in FIG. Figure 5 In other exemplary embodiments, the dimples 112 may be oriented such that the dimples 112 are concave toward the base layer 72 and convex away from the base layer (e.g., as shown in FIG. Figure 5 ). Similarly, the orientation of dimples 112 may be non-uniform across first intermediate sheet 78A, second intermediate sheet 78B, and sheet 82. In certain exemplary embodiments, one of first intermediate sheet 78A, second intermediate sheet 78B, and sheet 82 may have dimples 112 oriented in a first direction (e.g., recessed away from base layer 72), while another of first intermediate sheet 78A, second intermediate sheet 78B, and sheet 82 may have dimples 112 oriented in a second direction opposite to the first direction (e.g., recessed toward base layer 72).

[0071] In this example, the dimples 112 may be formed during the layer-by-layer additive manufacturing of each of the first intermediate sheet 78A, the second intermediate sheet 78B, and the sheet 82 used to build the lattice layer 74 .

[0072] In certain exemplary embodiments, the dimples 112 are shallow enough so that the drag force through the dimples 112 is much less than that through exposed (e.g., uncovered) honeycomb cells because the sheet 82 is a continuous or substantially continuous surface. More specifically, in at least certain exemplary aspects, the dimple surface of the sheet 82 can reduce the overall drag force on the stator (corresponding to the insert 70') compared to different examples of the insert 70' having a smooth, non-dimpled surface.

[0073] Here, dimples 112 serve to provide enhanced thermal strain relief for first intermediate sheet 78A, second intermediate sheet 78B, sheet 82, and lattice layer 74 as a whole. For example, during operation of propulsion system 10, lattice layer 74 of insert 70' may absorb thermal energy from the surrounding environment (e.g., directly from rotating seal elements), causing individual components of lattice layer 74 to expand. The curvature of dimples 112 allows dimples 112 to bulge as dimples 112 expand, thereby providing more space for each dimple 112 to grow due to thermal expansion without rupturing. When each of first intermediate sheet 78A, second intermediate sheet 78B, sheet 82, and wall 88 thermally expands during operation, the reduced local thermal strain at dimples 112 also reduces the thermal strain applied to base layer 72.

[0074] Now refer to Figure 6 , Figure 6 is a cross-sectional view of an insert 70" according to another exemplary embodiment of the present disclosure. The insert 70" may be Figure 3 The exemplary insert 70 is constructed in a similar manner.

[0075] However, for Figure 6 In the exemplary embodiment, the insert 70" includes cells 114 with filler material 116 disposed therein. The cells 114 are voids defined by the walls 88 of the insert 70". In this exemplary embodiment, the cells 114 also extend from the base layer 72 and span all of the lattice layers 74. However, it should be understood that in other exemplary embodiments, the cells 114 may be further divided and defined by intermediate sheets (see, e.g., FIG. 1 ). Figures 2 to 5 The intermediate sheets 78, 78A and 78B are shown in FIG.

[0076] Filler material 116 is a porous filler material, such as a matrix of metal fibers. More specifically, in at least some exemplary embodiments, filler material 116 may include austenitic stainless steel, FeCrAlY alloy, FeCrAlY composite material, or any combination thereof. In this example, filler material 116 is highly wear-resistant.

[0077] Filling material 116 may be applied to cells 100 of insert 70″ such that cells 114 are filled with filling material 116 (or such that filling material 116 fills each of a plurality of cells 114). In one exemplary embodiment, plasma spraying may be applied to each cell 114 individually prior to filling each cell 114 with filling material 116. In another exemplary embodiment, filling cells 114 with filling material 116 may include plasma spraying filling material 116 into cells 114. Each cell 114 is filled with filling material 116 to form a ridge along an upper edge of the cell 114 (e.g., Figure 6A smooth surface is shown facing upward toward the top surface of the insert 70).

[0078] During operation of the propulsion system 10, when the insert 70" rubs against the rotating seal element, the surface (the rotating seal element along its friction unit 114 and the filler material 116) creates a new smooth surface. In this case, the high wear resistance of the filler material 116 enables the insert 70 to create and maintain a smooth surface to continue interacting with the rotating seal element in the event of the friction event creating a new smooth surface.

[0079] In this manner, the insert 70″ having the filler material 116 creates a smooth surface due to the friction event, thereby providing a more effective fluid seal for air passing through the rotating seal element. Because the filler material 116 of the insert 70″ creates a more effective fluid seal, less air is allowed to pass through the rotating seal element, thereby reducing overall leakage through the insert 70″ when a friction event occurs.

[0080] As will be appreciated, the filler material 116 may be Figures 1 to 9 For example, filler material 116 may be added to any of first layer 76 , second layer 80 , first unit 100 , second unit 104 , and third unit 108 in any insert 70 or 70 ′ with or without sheet 82 .

[0081] Now refer to Figure 7 , Figure 7 1 is a simplified view of various shapes of units 114A to 110F according to an exemplary embodiment of the present disclosure. Figure 7 The units in FIG. 1 are referred to as units 114A to 110F, but it should be understood that units 114A to 110F may also refer to Figures 1 to 8 Any of the cells shown in any of the (e.g., the cell formed by the wall 88 and the middle sheet 78, the first cell 100, the second cell 104, and the third cell 108).

[0082] In this example, the views of cells 114A through 110F are top views of individual cells 114 of an insert (e.g., inserts 70, 70', 70"). Cell 114A includes a square cross-sectional shape. Cell 114B includes a diamond cross-sectional shape. Cell 114C includes a rhomboid cross-sectional shape. Cell 114D includes a rectangular cross-sectional shape. Cell 114F includes a hexagonal cross-sectional shape. Cell 114E includes a stretched diamond cross-sectional shape. In this manner, it should be understood that the cells of the present disclosure may define any suitable shape, such as a suitable triangle, quadrilateral, pentagon, hexagon, etc.

[0083] Now refer to Figure 8 , Figure 8 is a top isolated view of the middle sheet 78 according to an exemplary embodiment of the present disclosure.

[0084] like Figure 8 As shown, the middle sheet 78 defines a gap 118A and a gap 118B along the middle sheet 78 .

[0085] Gaps 118A and 118B are breaks or relief cuts defined or cut out of sections of the intermediate sheet 78. For this embodiment, the intermediate sheet 78 is shown as including gaps 118A and 118B. However, it should be understood that in other exemplary embodiments, any one of the first intermediate sheet 78A, the second intermediate sheet 78B, or the sheet 82, or a combination thereof, may include and / or define one or more of gaps 118A and 118B. In certain exemplary embodiments, gaps 118A and 118B may be formed when the intermediate sheet 78 is constructed using a layer-by-layer additive manufacturing process.

[0086] exist Figure 8 , gaps 118A and 118B are shown extending from one edge of the intermediate sheet 78 to the other edge of the intermediate sheet 78 along the second direction 86. Figure 8 As shown, gaps 118B also extend along first direction 84 to form a diagonal orientation along intermediate sheet 78. In certain exemplary embodiments, gaps 118A and 118B are defined by intermediate sheet 78 to include straight cuts of uniform width through intermediate sheet 78. However, it should be understood that in other exemplary embodiments, gaps 118A and / or 118B may be defined by intermediate sheet 78 to include non-straight cuts (e.g., spiral or otherwise curved) through intermediate sheet 78, with or without a constant width.

[0087] Gaps 118A and 118B provide a break in the continuity of the intermediate sheet 78 so that the intermediate sheet 78 does not form a complete 360° arc in place, while other intermediate sheets 78 of other inserts 70 are positioned to form a full circumferential ring. For example, if the intermediate sheet 78 were a continuous 360° ring, then in the event of high heat transfer from the honeycomb cell material to the intermediate sheet 78, the intermediate sheet 78 could try and grow faster than the base layer 72. In this case, the intermediate sheet 78 could grow radially outward faster than the base layer 72, causing the intermediate sheet 78 to push against the honeycomb cell material and potentially crush the honeycomb cell material against the base layer 72.

[0088] Gaps 118A, 118B may have any suitable width, such as between approximately A and B, such as between approximately C and D, such as between approximately E and F.

[0089] Gaps 118A and 118B provide thermal strain relief for the intermediate sheet 78 in the direction of expansion. For example, gaps 118A and 118B are locally located at certain points so that the intermediate sheet 78 does not crack or rupture when the intermediate sheet 78 expands due to linear thermal expansion in response to an increase in thermal energy (e.g., due to a friction event). In this way, gaps 118A and 118B enable the insert 70 (insert 70' or insert 70") to withstand high temperature differences along various portions of the insert 70 without causing the insert 70 to crack or rupture due to the insert 70's thermal linear expansion.

[0090] Now refer to Figure 9 , Figure 9 is a flow chart of a method 200 of manufacturing a wear-resistant insert (eg, insert 70 , insert 70 ′, or insert 70 ″) according to an exemplary embodiment of the present disclosure. The method 200 includes steps 202 - 220 .

[0091] Step 202 includes forming the base layer 72. In some exemplary embodiments, step 202 may include forming the base layer 72 using a layer-by-layer additive manufacturing process. However, it should be understood that in other exemplary embodiments, step 202 may include forming the base layer 72 using a non-additive manufacturing process.

[0092] Step 204 includes forming a lattice layer 74 connected to the base layer 72 by layer-by-layer additive manufacturing. Here, forming the lattice layer 74 may include step 206 of forming a series of walls 88 defining a plurality of cells (e.g., first cell 100, second cell 104, third cell 108, or cell 114). Step 204 may also include step 208 of filling one of the plurality of cells with a filler material 116 (e.g., a matrix of metal fibers).

[0093] Step 210 includes forming the intermediate layer 78 such that the intermediate layer 78 is disposed between the layer 82 and the base layer 72. In some exemplary embodiments, the intermediate layer 78 separates the plurality of cells into a first layer 76 of cells and a second layer 80 of cells. In other exemplary embodiments, step 210 may include forming 212 a plurality of dimples 112 in the intermediate layer 78.

[0094] Step 214 includes forming the sheet layer 82 connected to the lattice layer 74 via layer-by-layer additive manufacturing. In certain exemplary embodiments, step 214 may include step 216 of integrally forming the lattice layer 74 and the sheet layer 82 together via layer-by-layer additive manufacturing so that the lattice layer 74 and the sheet layer 82 are a unitary piece of material.

[0095] In other exemplary embodiments, step 214 may further include step 218 of forming a plurality of dimples 112 in sheet 82. In certain exemplary embodiments, step 218 may include step 220 of aligning one dimple 112 in the plurality of dimples 112 with one of the plurality of cells (e.g., first cell 100, second cell 104, third cell 108, or cell 114).

[0096] It should be understood that the inserts described herein are examples only, and in other embodiments, an insert according to another exemplary embodiment may be provided. For example, the insert may include any suitable number of intermediate layers (e.g., 1, 2, 3, 4, 5, 6, 7, 8, 9, etc.). Alternatively, the insert may not include any intermediate layers. Similarly, while the inserts described herein primarily include outer layers, in other embodiments, the insert may not include outer layers, but may include one or more intermediate layers, filler material, or both.

[0097] This written description uses examples to disclose the present disclosure, including the best mode, and also to enable any person skilled in the art to practice the present disclosure, including making and using any devices or systems and performing any incorporated methods. The patentable scope of the present disclosure is defined by the claims, and may include other examples that occur to those skilled in the art. If such other examples include structural elements that do not differ from the literal language of the claims, or if they include equivalent structural elements with insubstantial differences from the literal language of the claims, they are intended to be within the scope of the claims.

[0098] Further aspects are provided by the subject matter of the following clauses:

[0099] A wear resistant insert for a gas turbine engine, the wear resistant insert comprising: a base layer; a lattice layer connected to the base layer, wherein the lattice layer includes a series of walls defining a plurality of cells; and a sheet layer connected to the lattice layer on a side of the lattice layer opposite the base layer, wherein the sheet layer is curved and includes a concave direction away from the base layer, wherein the lattice layer and the sheet layer are integrally formed together and are a unitary piece of material.

[0100] The wear resistant insert according to one or more of these clauses, wherein the thickness of each of the series of walls of the cell layer and the thickness of the sheet layer are equal to or less than 5.0 thousandths of an inch.

[0101] The wear-resistant insert according to one or more of these clauses further comprises an intermediate layer, wherein the intermediate layer is arranged between the layer and the base layer, wherein the intermediate layer divides the plurality of cells into a first layer of cells and a second layer of cells.

[0102] The wear resistant insert according to one or more of these clauses, wherein the ply, the intermediate ply, or both, comprises a plurality of dimples, wherein each dimple of the plurality of dimples is aligned with a cell of the plurality of cells.

[0103] A wear insert according to one or more of these clauses, wherein the intermediate layer defines a relief gap extending through a portion of the intermediate layer.

[0104] A wear insert according to one or more of these clauses, wherein the intermediate layer is curved in a first direction, wherein the intermediate layer is flat in a second direction, wherein the second direction is perpendicular to the first direction, and wherein the relief gap extends in the second direction.

[0105] The wear resistant insert of one or more of these clauses, wherein the wear resistant insert defines a joint between the series of walls and one of the plies or the intermediate plies, and wherein the maximum thickness of the joint is equal to or less than 10.0 thousandths of an inch.

[0106] The wear resistant insert according to one or more of these clauses, wherein the sheet defines a flow path surface wall of the gas turbine engine.

[0107] The wear resistant insert according to one or more of these clauses, wherein the wear resistant insert is configured to form a sealing interface with a labyrinth seal of a low pressure turbine of the gas turbine engine.

[0108] A wear resistant insert according to one or more of these clauses, wherein the cross-sectional shape of each cell of the plurality of cells comprises a quadrilateral.

[0109] A wear resistant insert according to one or more of these clauses, wherein the cross-sectional shape of each cell of the plurality of cells comprises a rhombus.

[0110] The wear resistant insert according to one or more of these clauses, wherein the material of the wear resistant insert comprises a nickel alloy having a temperature threshold greater than 700 degrees Fahrenheit.

[0111] The wear resistant insert according to one or more of these clauses, wherein the material of the wear resistant insert comprises a nickel-chromium-aluminum-iron alloy or a nickel-molybdenum alloy.

[0112] The wear resistant insert according to one or more of these clauses, further comprising a porous filler material provided in a cell of the plurality of cells, wherein the porous filler material fills the cell of the plurality of cells.

[0113] The wear resistant insert according to one or more of these clauses, wherein the porous filling material comprises a matrix of metal fibers, wherein the material of the porous filling material comprises austenitic stainless steel, FeCrAlY alloy, FeCrAlY composite material or any combination thereof.

[0114] A method of manufacturing a wear-resistant insert for a gas turbine engine, the method comprising: forming a lattice layer connected to a base layer by layer-by-layer additive manufacturing, wherein forming the lattice layer comprises forming a series of walls defining a plurality of cells; and forming a sheet layer connected to the lattice layer by layer-by-layer additive manufacturing, wherein the sheet layer is curved and includes a concave direction facing away from the base layer, wherein the lattice layer and the sheet layer are integrally formed together via the layer-by-layer additive manufacturing and are a unitary piece of material.

[0115] The method of one or more of these clauses, further comprising forming a plurality of dimples in the sheet, wherein dimples in the plurality of dimples are aligned with cells in the plurality of cells.

[0116] The method of one or more of these clauses, further comprising forming an intermediate sheet, wherein the intermediate sheet is disposed between the sheet and the base layer, wherein the intermediate sheet separates the plurality of cells into a first layer of cells and a second layer of cells.

[0117] The method of one or more of these clauses, further comprising forming a plurality of depressions in the intermediate sheet.

[0118] The method of one or more of these clauses, further comprising filling cells of the plurality of cells with a matrix of metal fibers.

[0119] A wear resistant insert for a gas turbine engine, the wear resistant insert comprising: a base layer; a lattice layer connected to the base layer, wherein the lattice layer comprises a series of walls defining a plurality of cells; and a porous filler material disposed in cells of the plurality of cells, wherein the porous filler material comprises a matrix of metal fibers, wherein each wall of the series of walls of the lattice layer has a thickness equal to or less than 5.0 thousandths of an inch.

Claims

1. A wear-resistant insert for a gas turbine engine, characterized in that The wear-resistant insert comprises: grassroots; a lattice layer connected to the base layer, wherein the lattice layer includes a series of walls defining a plurality of cells; a sheet layer connected to the lattice layer on a side of the lattice layer opposite the base layer, wherein the sheet layer is curved and includes a concave direction facing away from the base layer; and an intermediate sheet layer, wherein the intermediate sheet layer is disposed between the sheet layer and the base layer, wherein the intermediate sheet layer divides the plurality of units into a first layer of units and a second layer of units, The sheet, the intermediate sheet, or both comprise a plurality of dimples, wherein each dimple of the plurality of dimples is aligned with a cell of the plurality of cells.

2. The wear-resistant insert according to claim 1, characterized in that in, The thickness of each wall of the series of walls of the lattice layer and the thickness of the sheet layer are equal to or less than 5.0 thousandths of an inch.

3. The wear-resistant insert according to claim 1, characterized in that in, The middle sheet defines a relief gap extending through a portion of the middle sheet.

4. The wear-resistant insert according to claim 3, characterized in that in, The middle sheet is curved along a first direction, wherein the middle sheet is flat along a second direction, wherein the second direction is perpendicular to the first direction, and wherein the relief gap extends in the second direction.

5. The wear-resistant insert according to claim 1, characterized in that in, The wear insert defines a joint between the series of walls and one of the plies or the intermediate plies, and wherein a maximum thickness of the joint is equal to or less than 10.0 thousandths of an inch.

6. The wear-resistant insert according to claim 1, characterized in that in, The sheets define flow path surface walls of the gas turbine engine.

7. The wear-resistant insert according to claim 1, characterized in that in, The wear resistant insert is configured to form a sealing interface with a labyrinth seal of a low-pressure turbine of the gas turbine engine.

8. The wear-resistant insert according to claim 1, characterized in that in, A cross-sectional shape of each of the plurality of cells includes a quadrilateral.

9. The wear-resistant insert according to claim 8, characterized in that in, A cross-sectional shape of each of the plurality of cells includes a rhombus.

10. The wear-resistant insert according to claim 1, characterized in that in, The material of the wear insert comprises a nickel alloy having a temperature threshold greater than 700 degrees Fahrenheit.

11. The wear-resistant insert according to claim 10, characterized in that in, The material of the wear-resistant insert includes a nickel-chromium-aluminum-iron alloy or a nickel-molybdenum alloy.

12. The wear-resistant insert according to claim 1, wherein Further included is a porous filling material disposed in a cell of the plurality of cells, wherein the porous filling material fills the cell of the plurality of cells.

13. The wear-resistant insert according to claim 12, characterized in that in, The porous filling material comprises a matrix of metal fibers, wherein the material of the porous filling material comprises austenitic stainless steel, FeCrAlY alloy, FeCrAlY composite material, or any combination thereof.

14. A method of manufacturing a wear-resistant insert for a gas turbine engine, characterized in that The method comprises: forming a lattice layer connected to the base layer by layer-by-layer additive manufacturing, wherein forming the lattice layer includes forming a series of walls defining a plurality of cells; forming a sheet connected to the lattice layer by layer-by-layer additive manufacturing, wherein the sheet is curved and includes a concave direction facing away from the base layer; forming an intermediate sheet, wherein the intermediate sheet is disposed between the sheet and the base layer, wherein the intermediate sheet divides the plurality of cells into a first layer of cells and a second layer of cells; and A plurality of dimples are formed in the sheet, the intermediate sheet, or both, wherein dimples in the plurality of dimples are aligned with cells in the plurality of cells.

15. The method according to claim 14, characterized in that Further comprising filling cells of the plurality of cells with a matrix of metal fibers.

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