In-Module Repair of Engine Seal Teeth Ceramic Top Layers

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Solution Overview

Problem

Existing gas turbine engine inter-stage seals, particularly those with seal teeth, face issues with maintainability and reliability due to uneven temperature distributions and spallation of the ceramic-based top layer, requiring complete component replacement and dismantling of the engine.

Innovation Solution

A new material composition and method for repairing the ceramic-based top layer of seal teeth in-module, using a slurry composition with sintering additives like low melting glass and a nucleating agent, applied at room temperature and cured with localized heat treatment at lower temperatures to restore toughness and adhesion.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of repair

If the ceramic-based top layer is repaired using traditional methods, then the component must be completely replaced, but this requires dismantling the engine and increases downtime

Engineering Contradiction:

Improverepair accessibilityVSAvoidengine downtime

Core Design Contradiction:

Ease of repairVSLoss of time

Solution Approach 1:

The repair process is segmented into distinct steps: cleaning the spalled area, applying the slurry composition, and curing with localized heat treatment. This allows the repair to be performed in-module without complete disassembly, significantly reducing engine downtime while maintaining repair quality

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The slurry composition acts as an intermediary material that bonds to the underlying layers and provides the protective ceramic function. This intermediary layer enables repair without complete component replacement, allowing in-module servicing and reducing maintenance time

Inventive Principle:

Principle #24Intermediary (Mediator)

2Strength

If high temperature curing is applied to repair the ceramic layer, then the material properties are restored, but the underlying layers may be damaged

Engineering Contradiction:

Improveceramic layer toughnessVSAvoidheat damage to underlying layers

Core Design Contradiction:

StrengthVSObject-affected harmful factors

Solution Approach 1:

The curing process applies heat locally only to the spalled area where the ceramic layer needs repair, rather than heating the entire component. This localized approach restores the ceramic material properties while protecting the underlying layers from thermal damage

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The slurry composition is formulated to cure at lower temperatures than traditional ceramic repair methods. By changing the curing temperature parameter, the repair process restores ceramic toughness while avoiding heat damage to the underlying metallic and bond coat layers

Inventive Principle:

Principle #35Parameter changes

3Reliability

If the entire component is stripped and recoated for repair, then the ceramic layer integrity is restored, but the manufacturing complexity and cost increase

Engineering Contradiction:

Improveceramic layer integrityVSAvoidrepair process complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The damaged ceramic top layer is selectively removed only from the spalled area rather than stripping the entire component. This extraction approach restores ceramic integrity locally while avoiding the complex and costly process of complete component disassembly and recoating

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The slurry composition is applied directly to the prepared surface and cured in-place, recovering the protective ceramic function without requiring complete component disassembly. This approach restores reliability while simplifying the repair process compared to full stripping and recoating

Inventive Principle:

Principle #34Discarding and recovering

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

The solution enables in-module repair of seal teeth, maintaining the integrity of the underlying layers, providing erosion resistance, and ensuring minimal downtime by allowing repair without dismantling the engine, while also matching the density and adhesion properties of the original ceramic-based top layer.

Implementation Method 1

a material composition and method for repairing the ceramic-based top layer of seal teeth in-module, using a slurry composition with sintering additives like low melting glass

Methodology Applied

Scientific EffectSintering: Sintering

Implementation Method 2

applied at room temperature and cured with localized heat treatment at lower temperatures to restore toughness and adhesion

Methodology Applied

Scientific EffectHeat treatment: Heat Treatment

Data Source

PatentUS20250073829A1System and method of repairing a multi-layer component of an engine

Publication Date: 2025.03.06 GENERAL ELECTRIC CO

AI summary

A method of repairing a multi-layer component of an engine in-module includes identifying a damage location on the multi-layer component. The damage location extends at least partially into a ceramic-based top layer of the multi-layer component. The method further includes depositing a material composition onto the damage location at a first temperature range so as to cover the damage location. The material composition includes one or more sintering additives. Further, the method includes applying localized curing to the material composition deposited at the damage location at a second temperature range, the second temperature range being higher than the first temperature range.