Systems and methods for forming a turbine engine shroud element with an integral sacrificial ring

Abstract

Turbine engine seals can prevent or reduce airflow along a surface of a turbine engine, such as along the turbine engine shroud or along the rotor. A 3D printer can be used for producing a turbine engine seal such as a brush seal or a labyrinth seal. Such a seal may be formed as a single piece that includes a hard ring and a sacrificial ring. The sacrificial ring and the hard ring may be circularly symmetric. The sacrificial ring is formed on an inside surface of the hard ring.

Description

SYSTEMS AND METHODS FOR FORMING A TURBINE ENGINE SHROUD ELEMENTWITH AN INTEGRAL SACRIFICIAL RINGCROSS REFERENCE TO RELATED APPLICATIONS

[0001] This patent application claims the priority and benefit of U.S. provisional patent application no. 63 / 615,673, titled “SYSTEMS AND METHODS FOR FORMING A TURBINE ENGINE SHROUD ELEMENT WITH AN INTEGRAL SACRIFICIAL RING” filed on December 28, 2023. U.S. provisional patent application no. 63 / 615,673 is herein incorporated by reference in its entirety.TECHNICAL FIELD

[0002] The systems and methods relate to additive manufacturing, 3D printing, and selective laser melting (SLM) printing of 3D objects. The systems and methods also relate to using additive manufacturing techniques to produce turbine engine elements with integral sacrificial rings such as those of honeycomb seals.BACKGROUND

[0003] Turbine engines use sacrificial seals to reduce airflow that passes outboard of the turbine blade tips or along the rotor. A common sacrificial seal material is a metallic honeycomb. The honeycomb is welded to a backing plate that can be bolted into the turbine engine to form brush seals and labyrinth seals. A brush seal may be located outboard of a turbine. The turbine’s turbine blades may impact the honeycomb without being damaged. The turbine blades may carve grooves into the honeycomb. The brush seal may thereby reduce the airflow along the shroud instead of through the turbine. A labyrinth seal may be located along the outside surface of the turbine rotor. Labyrinth seal teeth attached to the rotor can impact the honeycomb of the labyrinth seal to thereby reduce airflow from passing alongside the rotor instead of through the turbine. Those familial' with turbines or turbine engines are familiar with brush seals and labyrinth seals.BRIEF SUMMARY

[0004] The following summary is provided to facilitate an understanding of some of the innovative features unique to the examples disclosed and is not intended to be a full description. A full appreciation of the various aspects of the examples can be gained by taking the entire specification, claims, drawings, and abstract as a whole.

[0005] One aspect of the subject matter described in this disclosure can be implemented by a system. The system can include a seal configured to reduce airflow along a surface of a turbine engine, wherein the seal is formed as a single piece that includes a hard ring and a sacrificial ring, the sacrificial ring and the hard ring are circularly symmetric, and the sacrificial ring is formed on an inside surface of the hard ring.

[0006] Another aspect of the subject matter described in this disclosure can be implemented by a method. The method can include producing a seal that is formed as a single piece that includes a hard ring and a sacrificial ring, wherein the seal is configured to reduce airflow along a surface of a turbine engine, the sacrificial ring and the hard ring are circularly symmetric, and the sacrificial ring is formed on an inside surface of the hard ring.

[0007] Yet another aspect of the subject matter described in this disclosure can be implemented by a system. The system can include a turbine engine shroud that is formed as a unitary piece that includes a first sacrificial ring and a second sacrificial ring, wherein the turbine engine shroud and the first sacrificial ring are configured to form a brush seal of a turbine engine, and the turbine engine shroud and the second sacrificial ring arc configured to form an outer portion of a labyrinth seal of the turbine engine.

[0008] In some implementations of the methods and devices, the hard ring is a brush seal that is configured to surround a turbine rotor that includes a plurality of turbine blades, and the sacrificial ring is configured to be impacted by the turbine blades without damaging the turbine blades. In some implementations of the methods and devices, the seal is a non-rotating element of the turbine engine. In some implementations of the methods and devices, the seal is additively manufactured. In some implementations of the methods and devices, the seal is configured to form an outer portion of alabyrinth seal of the turbine engine, the sacrificial ring is an abradable lining that is configured to be abraded by a plurality of labyrinth seal teeth of the labyrinth seal, the labyrinth seal teeth are attached to a rotor of the turbine engine, and the sacrificial ring is a non-rotating element of the turbine engine. In some implementations of the methods and devices, the seal is a 3D printed seal. In some implementations of the methods and devices, a turbine engine shroud includes the hard ring. In some implementations of the methods and devices, the system may further include a turbine engine shroud that includes the hard ring and a second sacrificial ring that is attached to the inside surface of the turbine engine shroud, wherein the turbine engine shroud, the sacrificial ring, and the second sacrificial ring are formed as a unitary piece. Furthermore, the turbine engine shroud, the sacrificial ring, and the second sacrificial ring are circularly symmetric around a common axis, the turbine engine shroud and the sacrificial ring are configured to form a brush seal of the turbine engine, and the turbine engine shroud and the second sacrificial ring are configured to form an outer portion of a labyrinth seal of the turbine engine.

[0009] In some implementations of the methods and devices, the method may include using a 3D printer to print a turbine engine shroud that includes the seal. In some implementations of the methods and devices, the seal is configured to form a brush seal of the turbine engine that includes a turbine rotor that includes a plurality of turbine blades, and the brush seal is configured to surround the turbine rotor and to be impacted by the turbine blades without damaging the turbine blades. In some implementations of the methods and devices, the seal is a non-rotating element of the turbine engine. In some implementations of the methods and devices, the method may include using a 3D printer to print the seal as the single piece that includes the hard ring and the sacrificial ring. In some implementations of the methods and devices, the seal is configured to form an outer portion of a labyrinth seal of the turbine engine, and the sacrificial ring is an abradable lining that is configured to be abraded by a plurality of labyrinth seal teeth of the labyrinth seal, wherein the labyrinth seal teeth are attached to a rotor of the turbine engine, and the sacrificial ring is a non-rotating element of the turbine engine. In some implementations of the methods and devices, a turbine engine shroud includes the hard ring. In some implementations of the methods and devices, the method may include using a 3D printer to print a turbine engine shroud that includes the hard ring and that includes a second sacrificial ring that is attached to the inside surface of the turbine engine shroud, wherein the turbine engine shroud, the sacrificial ring, and the second sacrificial ring are formed as a unitary piece, the turbine engine shroud, the sacrificial ring, and the second sacrificial ring are circularly symmetricaround a common axis, the turbine engine shroud and the sacrificial ring are configured to form a brush seal of the turbine engine, and the turbine engine shroud and the second sacrificial ring are configured to form an outer portion of a labyrinth seal of the turbine engine.

[0010] In some implementations of the methods and devices, the turbine engine shroud is additively manufactured as the unitary piece. In some implementations of the methods and devices, the turbine engine shroud, the first sacrificial ring, and the second sacrificial ring are circularly symmetric around a common axis. In some implementations of the methods and devices, the first sacrificial ring includes a honeycomb material.BRIEF DESCRIPTION OF THE DRAWINGS

[0011] The accompanying figures, in which like reference numerals refer to identical or functionally similar elements throughout the separate views and which are incorporated in and form a part of the specification, further illustrate the examples and, together with the detailed description, serve to explain the examples disclosed herein.

[0012] FIG. 1 is an image of honeycomb material that may be used as a sacrificial element of a turbine engine seal.

[0013] FIG. 2 is a high level conceptual diagram that illustrates a section of a turbine engine seal that has honeycomb material welded to a hard ring section.

[0014] FIG. 3 is a high-level conceptual figure of a SLM style 3D printer, according to some aspects.

[0015] FIG. 4 is a high-level conceptual diagram illustrating an example of a 3D printed seal, according to some aspects.

[0016] FIG. 5 is a high level conceptual diagram that illustrates an example of a brush seal, according to some aspects.

[0017] FIG. 6 is a high level conceptual diagram that illustrates an example of a labyrinth seal, according to some aspects.

[0018] FIG. 7 is a high level conceptual diagram that illustrates an example of a 3D printed turbine engine shroud and a rotor, according to some aspects.

[0019] FIG. 8 is a high level conceptual diagram that illustrates a turbine engine shroud being printed by a 3D printer, according to some aspects.

[0020] FIG. 9 is a high level flow diagram that illustrates an example of a method for forming a seal with an integral sacrificial ring, according to some aspects.

[0021] FIG. 10 is a high level flow diagram that illustrates an example of a method for forming a turbine engine shroud element with an integral sacrificial ring, according to some aspects.DETAILED DESCRIPTION

[0022] The particular values and configurations discussed in the following non-limiting examples can be varied and are cited merely to illustrate one or more examples and are not intended to limit the scope thereof.

[0023] Examples will now be described more fully hereinafter with reference to the accompanying drawings, in which illustrative examples are shown. The examples disclosed herein can be embodied in many different forms and should not be construed as limited to the examples set forth herein; rather, these examples are provided so that this disclosure will be thorough and complete, and will fully convey the scope of the examples to those skilled in the art. Like numbers refer to like elements throughout.

[0024] The terminology used herein is for the purpose of describing particular examples only and is not intended to be limiting. As used herein, the singular forms "a", "an", and "the" are intended to include the plural forms as well, unless the context clearly indicates otherwise. It will be furtherunderstood that the terms "comprise" and / or "comprising," when used in this specification, specify the presence of stated features, integers, steps, operations, elements, and / or components, but do not preclude the presence or addition of one or more other features, integers, steps, operations, elements, components, and / or groups thereof.

[0025] Throughout the specification and claims, terms may have nuanced meanings suggested or implied in context beyond an explicitly stated meaning. Likewise, the phrase “in one example” as used herein does not necessarily refer to the same example and the phrase “in another example” as used herein does not necessarily refer to a different example. It is intended that claimed subject matter include combinations of examples in whole or in pail.

[0026] Unless otherwise defined, all terms (including technical and scientific terms) used herein have the same meaning as commonly understood by one of ordinary skill in the art. It will be further understood that terms, such as those defined in commonly used dictionaries, should be interpreted as having a meaning that is consistent with their meaning in the context of the relevant art and will not be interpreted in an idealized or overly formal sense unless expressly so defined herein.

[0027] It will be understood that particular examples described herein are shown by way of illustration and not as limitations to the claims. The principal aspects can be employed in various examples without departing from the scope of the claims. Those skilled in the art will recognize or be able to ascertain using no more than routine experimentation, numerous equivalents to the specific procedures described herein. Such equivalents are considered to be within the scope covered by the claims.

[0028] The use of the word “a” or “an” when used in conjunction with the term “comprising” in the claims and / or the specification may mean “one,” but it is also consistent with the meaning of “one or more,” “at least one,” and “one or more than one.” The use of the term “or” in the claims is used to mean “and / or” unless explicitly indicated to refer to alternatives only or the alternatives are mutually exclusive, although the disclosure supports a definition that refers to only alternatives and “and / or.” Throughout this application, the term “about” is used to indicate that a value includes the inherent variation of error for the device, the method being employed to determine the value, or the variation that exists among the study subjects.

[0029] As used in this specification and claim(s), the words “comprising” (and any form of comprising, such as “comprise” and “comprises”), “having” (and any form of having, such as “have” and “has”), “including” (and any form of including, such as “includes” and “include”) or “containing” (and any form of containing, such as “contains” and “contain”) are inclusive or open-ended and do not exclude additional, unrecited elements or method steps.

[0030] The term “or combinations thereof’ as used herein refers to all permutations and combinations of the listed items preceding the term. For example, “A, B, C, or combinations thereof’ is intended to include at least one of: A, B, C, AB, AC, BC, or ABC, and if order is important in a particular context, also BA, CA, CB, CBA, BCA, ACB, BAC, or CAB. Continuing with this example, expressly included are combinations that contain repeats of one or more item or term, such as BB, AAA, AB, BBC, AAABCCCC, CBBAAA, CABABB, and so forth. The skilled artisan will understand that typically there is no limit on the number of items or terms in any combination, unless otherwise apparent from the context.

[0031] All the compositions and / or methods disclosed and claimed herein can be made and executed without undue experimentation in light of the present disclosure. While the compositions and methods have been described in terms of preferred embodiments, it will be apparent to those of skill in the art that variations may be applied to the compositions and / or methods and in the steps or in the sequence of steps of the method described herein without departing from the concept, spirit, and scope thereof. All such similar- substitutes and modifications apparent to those skilled in the art are deemed to be within the spirit, scope and concept defined by the appended claims.

[0032] FIG. 1 is an image of honeycomb material 100 that may be used as a sacrificial element of a turbine engine seal. Those familiar with turbines and turbine engines are familiar with such honeycomb material 100. The honeycomb material 100 is designed and produced such that a turbine blade or other turbine rotor element is not damaged upon impact with the honeycomb material 100. The honeycomb material is therefore an abradable element that can be abraded by rotating elements (e.g., rotor blades, labyrinth seal teeth, etc.) that carve channels in the honeycomb material 100 while the rotor spins. The result is that seals may be created that reduce or prevent airflow along the sides of the turbine engine shroud or along the turbine rotor such that substantially all the air flows through theturbine. The seals may thereby help increase the efficiency of the turbine. The figure shows a honeycomb consisting of six sided cells. As is known in the art, other cell sizes and shapes may be used in a sacrificial element.

[0033] FIG. 2 is a high level conceptual diagram that illustrates a section 200 of a turbine engine seal that has honeycomb material 100 welded to a hard ring section 201. Those familiar with turbines and turbine engines are familiar with honeycomb seal sections such as that illustrated in FIG. 2. The illustrated example has a flange 202 and a hard ring section 201 that may be machined from a single piece of metal. The sacrificial element 203 may be welded to or otherwise adhered to the hard ring to produce a section 200 of a honeycomb seal. Note that the seal is often referred to as a honeycomb seal regardless of the shape of the cells in the sacrificial element. The honeycomb seal sections may be bolted to a turbine engine casing via mounting holes in the flange. A number of honeycomb seal sections may thus form a complete ring to thereby provide a honeycomb seal that reduces or prevents airflow along a rotor or surface of a turbine shroud.

[0034] FIG. 3 is a high-level conceptual figure of a SLM style 3D printer 300, according to some aspects. A powder feeder 310 deposits powder 312 to produce a powder layer 305 in a powder bed 308. The powder layer that is deposited first can lie directly on the powder bed 308 or on a substrate that may be placed in the powder bed before the powder layers are deposited. A beam scanner 301 can move a beam source 302 or steer an energy beam 311 that is produced by the beam source 302. The energy beam may be a laser beam, an electron beam, etc. The energy beam 311 produces a melt pool304 where the energy beam 311 melts some of the powder in the powder layer 305. The powder layer305 is the layer that is currently the topmost layer in the powder bed 308. The melt pool 304 has a melt pool depth 303. The melt pool depth 303 is illustrated as being large enough to melt the powder in the powder layer 305 as well as some of the patterned layer 306 directly underneath the powder layer 305. In some implementations the melt pool can extend down through numerous underlying layers. The beam scanner moves the melt pool 304 in a path through the powder layer 305 to selectively melt some of the powder and thereby produce a patterned layer. The powder layer that is deposited first becomes the bottom patterned layer 307. A 3D object may be printed by iteratively depositing a powder layer, using the energy beam to melt a pattern into the powder layer to produce a patterned layer, depositing another powder layer, and so forth to produce a stack of patterned layers forming the 3D object.

[0035] FIG. 4 is a high-level conceptual diagram illustrating an example of a 3D printed seal 400, according to some aspects. A 3D printed seal such as that shown in the example may be printed by a 3D printer such as that illustrated in FIG. 3. The entire 3D printed seal 400 can be printed at once as a unit and may thereby be formed as a single piece, also called a unitary piece, that includes a flange 402, a hard ring 405, and a sacrificial ring 406. Once printed the seal may be installed in a turbine engine via mounting holes 401 in the flange 402. The rotor of the turbine engine may rotate around a common axis 403 and can be circularly symmetric around that common axis 403. Other elements of the turbine engine, such as the seals (e.g., seal 400), may also be circularly symmetric around the common axis. The seal illustrated in FIG. 4 has a common axis 403 that may coincide with the common axis of the turbine engine and turbine rotor when the seal is in a turbine engine. The example of FIG. 4 has a flange 402, a hard ring 405, and a sacrificial ring 406 that are symmetrical around the common axis. 3D printers may easily print a seal that has a sacrificial ring having an inside surface 407 that is symmetrical around the common axis while the hard ring is not symmetrical around the common axis. Furthermore, the entire seal may be printed concurrently and as a single piece. As such, the sacrificial ring is attached to the inside surface of the hard ring because the sacrificial ring and the hard ring are printed as a single piece. As such, there is no need to weld the sacrificial element to the hard element.

[0036] FIG. 5 is a high level conceptual diagram that illustrates an example of a brush seal 500, according to some aspects. A brush seal 500 is a seal configured to surround a turbine rotor and to prevent airflow along the inside surface of a turbine engine shroud. Airflow along the inside surface of a turbine engine shroud may bypass the turbine 501, resulting in inefficient turbine operation. The turbine 501 may have numerous turbine blades 503 attached to a rotor 502. The brush seal 500 may be configured to surround the turbine 501. As such, the rotor, with turbine blades attached, may be positioned within the brush seal. The turbine 501, which includes the rotor 502 and the turbine blades 503, may spin inside the brush seal 500 such that the tips of the turbine blades 503 impact the sacrificial ring without damage to any of the turbine blades. Such impacts may carve gouges in the sacrificial ring. The brush seal 500 illustrated in FIG. 5 may be 3D printed as a single piece. The turbine 501, rotor 502, and turbine blades 503 may be rotating elements that spin inside the brush seal which is a non-rotating element that surrounds the non-rotating elements. The sacrificial ring 406 of the brush seal 500 may be an abradable lining configured to be abraded by turbine blades 503 attached to the rotor 502 and spinning inside the brush seal. The turbine blades 503 may abrade the sacrificial ring406 by carving grooves in the sacrificial ring 406.

[0037] FIG. 6 is a high level conceptual diagram that illustrates an example of a labyrinth seal 600, according to some aspects. As is known in the art, a turbine rotor 502 may be held in position within a turbine engine by bearing elements (not shown). The bearing elements hold the rotor in place while providing for substantially frictionless rotor rotation. Structures within the turbine engine, such as the bearing elements, provide an opportunity for airflow along the rotor. Air flowing along the rotor instead of through the turbine may result in inefficient turbine operation. A labyrinth seal 600 is a seal configured to prevent airflow along the rotor 502. The labyrinth seal 600 can include a hard ring 602, a sacrificial ring 601, and labyrinth seal teeth 606. The hard ring 602 and sacrificial ring 601 can be non-rotating elements that form an outer portion of the labyrinth seal. The labyrinth seal teeth 606 are attached to the rotor 502 and are therefore rotating elements. The labyrinth seal 600 may be formed by positioning the rotor inside the hard ring 602 and the sacrificial ring 601. As such, the hard ring 602 and the sacrificial ring 601 may be configured to surround the rotor 502 and the labyrinth seal teeth 606 attached to the rotor 502. The labyrinth seal teeth 606 may be attached to the rotor 502 such that the labyrinth seal teeth 606 may carve grooves in the sacrificial ring 601 as the rotor 502 spins. As such, the sacrificial ring 601 of the labyrinth seal 600 may be an abradable lining configured to be abraded by the labyrinth seal teeth 606 attached to the rotor 502 and spinning inside the labyrinth seal 600. The labyrinth seal teeth 606 may abrade the sacrificial ring 601 by carving grooves in the sacrificial ring 601. The labyrinth seal teeth 606 and the sacrificial ring 601 in combination form a labyrinthine path for air flowing along the rotor. Relative to a straight path, the labyrinthine path reduces airflow along the rotor. The example illustrated in FIG. 6 has spars 603 connecting the hard ring 602 to the flange. The flange, spars 603, hard ring 602, and sacrificial ring 601 may be 3D printed in a single run of a 3D printer and thereby formed as a single piece. The sacrificial ring is formed on the inside surface of the hard ring.

[0038] FIG. 7 is a high level conceptual diagram that illustrates an example of a 3D printed turbine engine shroud 700 and a rotor 502, according to some aspects. The turbine engine shroud 700 includes a brush seal 701, the hard ring 602 of a labyrinth seal 702, and the sacrificial ring 601 of the labyrinth seal 702. The labyrinth seal teeth can be seen attached to the rotor. In the example of FIG. 7, the turbine engine shroud 700 may be 3D printed and thereby formed as a single piece. The turbine engine shroud 700 can include the sacrificial ring 406 of a brush seal 701 while the turbine engine shroud itself maybe the hard ring supporting the sacrificial ring 406. As such, the hard ring of the brush seal 701 is equivalent to the portion of the turbine engine shroud 700 supporting the sacrificial ring 406 of the brush seal. Note that the function of a hard ring is to provide rigid support to the sacrificial ring. The turbine engine shroud can also include the spars 603, hard ring 602 for a labyrinth seal 702, and sacrificial ring 601 for a labyrinth seal 702. Here, a single turbine stage of a turbine engine is shown. The 3D printed turbine engine shroud may be configured with additional turbine stages and with additional stages of the turbine engine. A turbine engine may include only a single turbine engine shroud or many turbine engine shrouds attached end to end.

[0039] FIG. 8 is a high level conceptual diagram that illustrates a turbine engine shroud being printed by a 3D printer, according to some aspects. The 3D printer illustrated in FIG. 3 is printing the turbine engine shroud illustrated in FIG. 7.

[0040] FIG. 9 is a high level flow diagram that illustrates an example of a method for forming a seal with an integral sacrificial ring 900, according to some aspects. At block 901, a seal is produced that is formed as a single piece that includes a hard ring and a sacrificial ring, wherein the seal is formed as a single piece that includes a hard ring and a sacrificial ring, the sacrificial ring and the hard ring are circularly symmetric, and the sacrificial ring is formed on an inside surface of the hard ring.

[0041] FIG. 10 is a high level flow diagram that illustrates an example of a method for forming a turbine engine shroud element with an integral sacrificial ring 1000, according to some aspects. At block 1001, a 3D printer is used to print a turbine engine shroud that includes a sacrificial ring and a second sacrificial ring that is attached to the inside surface of the turbine engine shroud, wherein the turbine engine shroud, the sacrificial ring, and the second sacrificial ring arc formed as a unitary piece, the turbine engine shroud, the sacrificial ring, and the second sacrificial ring are circularly symmetric around a common axis, the turbine engine shroud and the sacrificial ring are configured to form a brush seal of a turbine engine, and the turbine engine shroud and the second sacrificial ring are configured to form an outer portion of a labyrinth seal of the turbine engine.

Claims

CLAIMSWhat is claimed is:

1. A system comprising: a seal configured to reduce airflow along a surface of a turbine engine, wherein: the seal is formed as a single piece that includes a hard ring and a sacrificial ring; the sacrificial ring and the hard ring are circularly symmetric; and the sacrificial ring is formed on an inside surface of the hard ring.

2. The system of claim 1, wherein: the hard ring is a brush seal that is configured to surround a turbine rotor that includes a plurality of turbine blades; and the sacrificial ring is configured to be impacted by the turbine blades without damaging the turbine blades.

3. The system of claim 1, wherein the seal is a non-rotating element of the turbine engine.

4. The system of claim 1, wherein the seal is additively manufactured.

5. The system of claim 1, wherein: the seal is configured to form an outer portion of a labyrinth seal of the turbine engine; the sacrificial ring is an abradable lining that is configured to be abraded by a plurality of labyrinth seal teeth of the labyrinth seal; the labyrinth seal teeth are attached to a rotor of the turbine engine; and the sacrificial ring is a non-rotating element of the turbine engine.

6. The system of claim 1, wherein the seal is a 3D printed seal.

7. The system of claim 1, wherein a turbine engine shroud includes the hard ring.

8. The system of claim 1, further including:a turbine engine shroud that includes the hard ring and a second sacrificial ring that is attached to the inside surface of the turbine engine shroud, wherein: the turbine engine shroud, the sacrificial ring, and the second sacrificial ring are formed as a unitary piece; the turbine engine shroud, the sacrificial ring, and the second sacrificial ring are circularly symmetric around a common axis; the turbine engine shroud and the sacrificial ring are configured to form a brush seal of the turbine engine; and the turbine engine shroud and the second sacrificial ring are configured to form an outer portion of a labyrinth seal of the turbine engine.

9. A method comprising: producing a seal that is formed as a single piece that includes a hard ring and a sacrificial ring, wherein: the seal is configured to reduce airflow along a surface of a turbine engine; the sacrificial ring and the hard ring are circularly symmetric; and the sacrificial ring is formed on an inside surface of the hard ring.

10. The method of claim 9, further including: using a 3D printer to print a turbine engine shroud that includes the seal.

11. The method of claim 9, wherein: the seal is configured to form a brush seal of the turbine engine that includes a turbine rotor that includes a plurality of turbine blades; and the brush seal is configured to surround the turbine rotor and to be impacted by the turbine blades without damaging the turbine blades.

12. The method of claim 9, wherein the seal is a non-rotating element of the turbine engine.

13. The method of claim 9, further including:using a 3D printer to print the seal as the single piece that includes the hard ring and the sacrificial ring.

14. The method of claim 9, wherein: the seal is configured to form an outer portion of a labyrinth seal of the turbine engine; and the sacrificial ring is an abradable lining that is configured to be abraded by a plurality of labyrinth seal teeth of the labyrinth seal, wherein: the labyrinth seal teeth are attached to a rotor of the turbine engine; and the sacrificial ring is a non-rotating element of the turbine engine.

15. The method of claim 9, wherein a turbine engine shroud includes the hard ring.

16. The method of claim 9, further including: using a 3D printer to print a turbine engine shroud that includes the hard ring and that includes a second sacrificial ring that is attached to the inside surface of the turbine engine shroud, wherein: the turbine engine shroud, the sacrificial ring, and the second sacrificial ring are formed as a unitary piece; the turbine engine shroud, the sacrificial ring, and the second sacrificial ring are circularly symmetric around a common axis; the turbine engine shroud and the sacrificial ring are configured to form a brush seal of the turbine engine; and the turbine engine shroud and the second sacrificial ring arc configured to form an outer portion of a labyrinth seal of the turbine engine.

17. A system comprising: a turbine engine shroud that is formed as a unitary piece that includes a first sacrificial ring and a second sacrificial ring, wherein: the turbine engine shroud and the first sacrificial ring are configured to form a brush seal of a turbine engine; andthe turbine engine shroud and the second sacrificial ring are configured to form an outer portion of a labyrinth seal of the turbine engine.

18. The system of claim 17, wherein the turbine engine shroud is additively manufactured as the unitary piece.

19. The system of claim 17, wherein the turbine engine shroud, the first sacrificial ring, and the second sacrificial ring are circularly symmetric around a common axis.

20. The system of claim 17, wherein the first sacrificial ring includes a honeycomb material.

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