Thin Nickel Superalloy Seal for Gas Turbine Engine
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Solution Overview
Problem
Conventional turbine airfoil seals are limited by material properties to environments below 2000 degrees Fahrenheit, restricting engine design and requiring seals with increased strength and temperature tolerance.
Innovation Solution
A seal formed from a sheet of precipitation hardened nickel base superalloy with a thickness of 0.010 to 0.050 inches, processed using techniques like electro discharge machining or rolling, and optionally coated with thermal or oxidation resistant coatings, to accommodate high temperatures and provide enhanced strength.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If conventional seal materials are used, then manufacturing and installation are straightforward, but temperature tolerance is limited to below 2000 degrees Fahrenheit
Solution Approach 1:
The patent changes the material parameters by using precipitation hardened nickel base superalloys with specific compositional ranges (e.g., 5-15% chromium, 3-8% cobalt, controlled carbon content) and specific heat treatment parameters (solution treating at 1900-2200°F, aging at 1000-1300°F) to achieve both high temperature tolerance above 2000°F and maintained material strength
Solution Approach 2:
The patent employs composite material structures including precipitation hardened nickel base superalloys with controlled precipitate phases (gamma prime, gamma double prime), and optionally combines metal matrix composites with ceramic particles or fibers to achieve superior high-temperature strength and creep resistance while maintaining ductility
2Length of moving object
If seal thickness is reduced to 0.010-0.050 inches, then the seal becomes thinner and more flexible, but manufacturing precision requirements increase
Solution Approach 1:
The patent specifies precise thickness parameters (0.010-0.050 inches) and controls manufacturing process parameters including rolling reduction ratios, annealing temperatures and times, and precision cutting parameters to achieve the required thickness tolerance of ±0.002 inches for thin seal sections
Solution Approach 2:
The patent employs hydraulic or pneumatic rolling mills with controlled pressure and temperature to uniformly reduce the seal thickness to precise dimensions, and uses precision hydraulic cutting systems to achieve accurate thickness control within ±0.002 inches tolerance
3Temperature
If precipitation hardened nickel base superalloys are used, then temperature tolerance increases, but material cost increases
Solution Approach 1:
The patent optimizes the alloy composition parameters within specific ranges (e.g., 5-15% chromium, 3-8% cobalt, 2-5% aluminum, 1-3% titanium) to achieve the minimum necessary temperature tolerance above 2000°F while controlling material cost, and specifies precise heat treatment parameters to maximize performance per unit cost
Solution Approach 2:
The patent applies selective coating strategies where thermal barrier coatings are applied only to high-temperature exposure areas, and oxidation-resistant coatings are applied selectively to surfaces exposed to oxidizing environments, reducing overall coating material cost while maintaining protection where needed
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 reliable operation at temperatures above 2000 degrees Fahrenheit, increasing the reliability and durability of gas turbine engines by providing seals that are not a design limitation, with improved strength and fatigue resistance.
Implementation Method 1
a precipitation hardened nickel base superalloy containing at least 40% by volume of the precipitate of the form Ni3(Al, X)
Implementation Method 2
applying at least one of a thermal barrier coating or an oxidation resistant metallic coating to the sheet in forming the seal
Implementation Method 3
applying at least one of a thermal barrier coating or an oxidation resistant metallic coating to the sheet in forming the seal
Data Source
AI summary
Aspects of the disclosure are directed to a seal configured to interface with at least a first component and a second component of a gas turbine engine. A method for forming the seal includes obtaining an ingot of a fine grained, or a coarse grained, or a columnar grained or a single crystal material from a precipitation hardened nickel base superalloy containing at least 40% by volume of the precipitate of the form Ni3(Al, X), where X is a metallic or refractory element, and processing the ingot to generate a sheet of the material, where the sheet has a thickness within a range of 0.010 inches and 0.050 inches inclusive.