Gas Turbine Seal Assembly With Abradable Coating for Wear Detection
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Solution Overview
Problem
Gas turbine engines face challenges in detecting wear in seal assemblies, which can lead to leakage and reduced efficiency, as existing technologies lack effective methods for monitoring seal condition during operation.
Innovation Solution
Incorporating an abradable coating with magnetic particles on a seal plate and a cutter on a static structure, where the cutter contacts the coating only in a worn seal condition, releasing magnetic particles that can be detected by sensors to indicate wear.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If traditional seal assemblies are used without wear detection mechanisms, then the device complexity is reduced, but the ability to detect seal wear is lost leading to leakage and reduced efficiency
Solution Approach 1:
The patent uses magnetic particles embedded in the abradable coating that can be detected by sensors. As the seal wears, the cutter contacts the coating and releases magnetic particles, which are then detected by sensors to indicate wear condition. This transforms the wear detection into a detectable signal without requiring complex monitoring systems.
Solution Approach 2:
The abradable coating with magnetic particles acts as an intermediary between the seal wear condition and the detection system. Instead of directly monitoring seal geometry or clearance, the magnetic particles serve as a mediator that can be easily detected by sensors, simplifying the overall detection system.
2Reliability
If the cutter contacts the abradable coating during normal operation, then wear detection is continuous, but the coating is excessively worn leading to premature seal failure
Solution Approach 1:
The system transitions from static seal contact to dynamic wear detection. The cutter is positioned to contact the abradable coating only under specific wear conditions, not during normal operation. This dynamic approach allows the seal to function normally while enabling detection when wear occurs.
Solution Approach 2:
The abradable coating is positioned radially outward of the normal contact area, creating a buffer zone. This preliminary positioning allows the seal to wear through the coating before the cutter makes contact, providing early warning of wear without causing excessive coating loss during normal operation.
3Measurement precision
If the abradable coating is positioned in the contact area, then wear detection is immediate, but the seal cannot function properly during normal operation
Solution Approach 1:
The seal interface is segmented into two distinct zones: a contact area for normal sealing operation and a detection area with the abradable coating. This segmentation allows the seal to function properly in the contact area while enabling wear detection in the separate coating area when wear progresses.
Solution Approach 2:
The abradable coating is positioned in a different radial dimension than the primary contact area. Instead of placing the coating directly in the contact zone, it is positioned radially outward, creating a layered structure that separates sealing function from detection function in the radial dimension.
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
Enables early detection of seal wear, preventing leakage and maintaining efficiency by allowing for timely maintenance, improving operational reliability and reducing downtime.
Implementation Method 1
an abradable coating with magnetic particles on a seal plate and a cutter on a static structure, where the cutter contacts the coating only in a worn seal condition, releasing magnetic particles that can be detected by sensors to indicate wear
Data Source
AI summary
A gas turbine engine according to an exemplary aspect of this disclosure includes, among other things, a compressor section, a combustor section, a turbine section, and at least one rotatable shaft. The gas turbine engine further includes a seal assembly including a static structure and a rotatable structure configured to meet to form a contact area. The seal assembly includes an abradable coating on one of the static structure and the rotatable structure, and the seal assembly further includes a cutter on the other of the static structure and the rotatable structure.