WALL DEPOSITION

Abstract

A method of forming a wall structure on a substrate comprises depositing, by additive-layer, powder-fed, laser-weld deposition apparatus, a plurality of material layers overlying one another on the substrate to form the wall structure. Each material layer of the plurality of material layers has (a) a layer thickness, measured in a direction locally perpendicular to a profile of the substrate, of no greater than about 350 μm and (b) a layer width, measured in a direction locally parallel to the profile of the substrate, of no greater than about 1200 μm.

Claims

1. A method of forming a wall structure on a substrate, the method comprising: depositing, by additive-layer, powder-fed, laser-weld deposition apparatus, a plurality of material layers overlying one another on the substrate (702) to form the wall structure; wherein each material layer of the plurality of material layers has (a) a layer thickness, measured in a direction locally perpendicular to a profile of the substrate, of no greater than about 350 μm and (b) a layer width, measured in a direction locally parallel to the profile of the substrate, of no greater than about 1200 μm.

2. The method according to claim 1, wherein the layer thickness of each material layer of the plurality of material layers is no less than about 50 μm.

3. The method according to claim 1, wherein the layer width of each material layer of the plurality of material layers is no less than about 50 μm.

4. The method according to claim 1, wherein the method comprises, during additive-layer, powder-fed, laser-weld deposition of the plurality of material layers: (i) controlling a powder spot size to be from about 0.1 mm to about 3 mm, for example from about 0.2 mm to about 0.5 mm; (ii) controlling a laser spot size to be from about 50 μm to about 1000 μm, for example from about 200 μm to about 600 μm; (iii) controlling a laser scanning speed to be from about 400 mm/minute to about 2000 mm/minute, for example from about 1000 mm/minute to about 1400 mm/minute; and/or (iv) controlling a powder feed rate to be from about 0.25 g/minute to about 10 g/minute, for example from about 1 g/minute to about 3 g/minute.

5. The method according to claim 1, wherein the method comprises: varying one or more deposition parameters of the additive-layer, powder-fed, laser-weld deposition apparatus during deposition of the plurality of material layers such that two or more material layers of the plurality of material layers have different layer widths.

6. The method according to claim 5, wherein the method comprises: varying one or more deposition parameters of the additive-layer, powder-fed, laser-weld deposition apparatus during deposition of the plurality of material layers such that each material layer deposited has a layer width which is less than or equal to the layer width of any previously deposited material layer of the plurality of material layers, thereby forming a wall structure having a tapered width profile along a direction locally perpendicular to the profile of the substrate.

7. The method according to claim 1, wherein the additive-layer, powder-fed, laser-weld deposition apparatus comprises a nozzle for supplying powdered material and a laser for generating a laser beam to fuse the powdered material to form each material layer, wherein, during deposition by the additive-layer, powder-fed, laser-weld deposition apparatus, the profile of the substrate is inclined at an oblique angle with respect to the laser beam, and wherein the method further comprises: adjusting the relative position of the substrate and the additive-layer, powder-fed, laser-weld deposition apparatus between deposition of each material layer of the plurality of material layers such that the wall structure formed extends substantially perpendicular to the profile of the substrate.

8. The method according to claim 1, wherein each material layer of the plurality of material layers comprises superalloy.

9. The method according to claim 8, wherein the superalloy is a nickel-based superalloy, for example a nickel-based superalloy comprising: from about 50 wt. % to about 85 wt. % Ni; from about 2 wt. % to about 8 wt. % Al; and the usual impurities; wherein the nickel-based superalloy optionally further comprises: from about 2 wt. % to about 15 wt. % Co, from about 3 wt. % to about 10 wt. % Cr, from about 1 wt. % to about 7 wt. % W, up to about 5 wt. % Re, about 4 wt. % to about 8 wt. % Ta, up to about 1 wt. % Si, up to about 3 wt. % Hf, up to about 3 wt. % Mo, up to about 1 wt. % Fe, up to about 1 wt. % Ti, up to about 1 wt. % Cu, up to about 0.04 wt. % C, and/or up to about 0.03 wt. B.

10. The method according to claim 1, wherein the substrate comprises superalloy, for example nickel-based superalloy, optionally wherein the substrate is monocrystalline.

11. The method according to claim 1, comprising forming the wall structure at room temperature.

12. The method according to claim 1, wherein the substrate is a gas turbine engine component.

13. The method according to claim 1, wherein the wall structure is a wall structure of a sealing element, for example an abradable sealing element.

14. An article manufactured by the method according to claim 1.

15. An article comprising a support and a wall structure extending from the support, wherein the wall structure has a wall width of no greater than about 1200 μm and a multi-layered microstructure, observed in cross-section in a plane locally perpendicular to a profile of the support, comprising a plurality of stacked weld layers, each of the weld layers having a layer thickness, measured in a stacking direction, of no greater than about 350 μm.

16. The article according to claim 15, wherein the layer thickness of each weld layer of the plurality of stacked weld layers is no less than about 50 μm.

17. The article according to claim 15, wherein the wall width of the wall structure is no less than about 50 μm.

18. The article according to claim 15, wherein each weld layer of the plurality of weld layers comprises superalloy, optionally wherein the superalloy is a nickel-based superalloy, for example a nickel-based superalloy comprising: from about 50 wt. % to about 85 wt. % Ni; from about 2 wt. % to about 8 wt. % Al; and the usual impurities; wherein the nickel-based superalloy optionally further comprises: from about 2 wt. % to about 15 wt. % Co, from about 3 wt. % to about 10 wt. % Cr, from about 1 wt. % to about 7 wt. % W, up to about 5 wt. % Re, about 4 wt. % to about 8 wt. % Ta, up to about 1 wt. % Si, up to about 3 wt. % Hf, up to about 3 wt. % Mo, up to about 1 wt. % Fe, up to about 1 wt. % Ti, up to about 1 wt. % Cu, up to about 0.04 wt. % C, and/or up to about 0.03 wt. B.

19. The article according to claim 15, wherein the article is a sealing element, for example an abradable sealing element.

20. The article according to claim 19, wherein the wall structure defines at least one cell filled with an abradable material.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0075] Embodiments will now be described by way of example only, with reference to the Figures, in which:

[0076] FIG. 1 is a sectional side view of a gas turbine engine;

[0077] FIG. 2 is a close up sectional side view of an upstream portion of a gas turbine engine;

[0078] FIG. 3 is a partially cut-away view of a gearbox for a gas turbine engine;

[0079] FIG. 4 is a partially cut-away view of a turbine seal segment for a high-pressure turbine of a gas turbine engine;

[0080] FIG. 5 is a perspective view of an example abradable seal element;

[0081] FIG. 6 is a plan view of the example abradable seal element of FIG. 5;

[0082] FIG. 7 is a cross-sectional view of the example abradable seal element of FIGS. 5 and 6;

[0083] FIG. 8 is a plan view of an example abradable seal element wall structure;

[0084] FIG. 9 is a plan view of an example abradable seal element;

[0085] FIG. 10 is a plan view of an example abradable seal element;

[0086] FIG. 11 is an illustration of the example abradable seal element of FIG. 10;

[0087] FIG. 12 is an optical micrograph of an etched cross-section through an abradable seal element;

[0088] FIG. 13 is a schematic illustration of additive-layer, powder-fed, laser-weld deposition apparatus;

[0089] FIG. 14 is a schematic illustration of a nozzle region of the apparatus of FIG. 13;

[0090] FIG. 15 is a schematic cross-sectional view of a multi-layered wall structure deposited on a substrate;

[0091] FIG. 16 is a schematic cross-sectional view of a multi-layered wall structure having a tapered width profile;

[0092] FIG. 17 is an optical micrograph of an etched cross-section through a multi-layered wall structure of an abradable seal element in which multiple, stacked weld layers and weld interfaces are visible;

[0093] FIG. 18 is a schematic illustration of deposition geometry for depositing a wall structure on a substrate in a constrained space;

[0094] FIG. 19 is a flowchart illustrating a method of forming a wall structure on a substrate;

[0095] FIG. 20 is an optical micrograph of a cross-section through a first example abradable seal element; and

[0096] FIG. 21 is an optical micrograph of an etched cross-section through a second example abradable seal element.

DETAILED DESCRIPTION OF THE DISCLOSURE

[0097] Aspects and embodiments of the present disclosure will now be discussed with reference to the accompanying figures. Further aspects and embodiments will be apparent to those skilled in the art.

Gas Turbine Engine

[0098] FIG. 1 illustrates a gas turbine engine 10 having a principal rotational axis 9. The engine 10 comprises an air intake 12 and a propulsive fan 23 that generates two airflows: a core airflow A and a bypass airflow B. The gas turbine engine 10 comprises a core 11 that receives the core airflow A. The engine core 11 comprises, in axial flow series, a low pressure compressor 14, a high-pressure compressor 15, combustion equipment 16, a high-pressure turbine 17, a low pressure turbine 19 and a core exhaust nozzle 20. A nacelle 21 surrounds the gas turbine engine 10 and defines a bypass duct 22 and a bypass exhaust nozzle 18. The bypass airflow B flows through the bypass duct 22. The fan 23 is attached to and driven by the low pressure turbine 19 via a shaft 26 and an epicyclic gearbox 30. A fan containment arrangement 31 extends around the fan 23 inboard the nacelle 21.

[0099] In use, the core airflow A is accelerated and compressed by the low pressure compressor 14 and directed into the high pressure compressor 15 where further compression takes place. The compressed air exhausted from the high pressure compressor 15 is directed into the combustion equipment 16 where it is mixed with fuel and the mixture is combusted. The resultant hot combustion products then expand through, and thereby drive, the high pressure and low pressure turbines 17, 19 before being exhausted through the core exhaust nozzle 20 to provide some propulsive thrust. The high pressure turbine 17 drives the high pressure compressor 15 by a suitable interconnecting shaft 27. The fan 23 generally provides the majority of the propulsive thrust. The epicyclic gearbox 30 is a reduction gearbox.

[0100] An exemplary arrangement for a geared fan gas turbine engine 10 is shown in FIG. 2. The low pressure turbine 19 (see FIG. 1) drives the shaft 26, which is coupled to a sun wheel, or sun gear, 28 of the epicyclic gear arrangement 30. Radially outwardly of the sun gear 28 and intermeshing therewith is a plurality of planet gears 32 that are coupled together by a planet carrier 34. The planet carrier 34 constrains the planet gears 32 to precess around the sun gear 28 in synchronicity whilst enabling each planet gear 32 to rotate about its own axis. The planet carrier 34 is coupled via linkages 36 to the fan 23 in order to drive its rotation about the engine axis 9. Radially outwardly of the planet gears 32 and intermeshing therewith is an annulus or ring gear 38 that is coupled, via linkages 40, to a stationary supporting structure 24.

[0101] Note that the terms “low pressure turbine” and “low pressure compressor” as used herein may be taken to mean the lowest pressure turbine stages and lowest pressure compressor stages (i.e. not including the fan 23) respectively and/or the turbine and compressor stages that are connected together by the interconnecting shaft 26 with the lowest rotational speed in the engine (i.e. not including the gearbox output shaft that drives the fan 23). In some literature, the “low pressure turbine” and “low pressure compressor” referred to herein may alternatively be known as the “intermediate pressure turbine” and “intermediate pressure compressor”. Where such alternative nomenclature is used, the fan 23 may be referred to as a first, or lowest pressure, compression stage.

[0102] The epicyclic gearbox 30 is shown by way of example in greater detail in FIG. 3. Each of the sun gear 28, planet gears 32 and ring gear 38 comprise teeth about their periphery to intermesh with the other gears. However, for clarity only exemplary portions of the teeth are illustrated in FIG. 3. There are four planet gears 32 illustrated, although it will be apparent to the skilled reader that more or fewer planet gears 32 may be provided within the scope of the claimed invention. Practical applications of a planetary epicyclic gearbox 30 generally comprise at least three planet gears 32.

[0103] The epicyclic gearbox 30 illustrated by way of example in FIGS. 2 and 3 is of the planetary type, in that the planet carrier 34 is coupled to an output shaft via linkages 36, with the ring gear 38 fixed. However, any other suitable type of epicyclic gearbox 30 may be used. By way of further example, the epicyclic gearbox 30 may be a star arrangement, in which the planet carrier 34 is held fixed, with the ring (or annulus) gear 38 allowed to rotate. In such an arrangement the fan 23 is driven by the ring gear 38. By way of further alternative example, the gearbox 30 may be a differential gearbox in which the ring gear 38 and the planet carrier 34 are both allowed to rotate.

[0104] It will be appreciated that the arrangement shown in FIGS. 2 and 3 is by way of example only, and various alternatives are within the scope of the present disclosure. Purely by way of example, any suitable arrangement may be used for locating the gearbox 30 in the engine 10 and/or for connecting the gearbox 30 to the engine 10. By way of further example, the connections (such as the linkages 36, 40 in the FIG. 2 example) between the gearbox 30 and other parts of the engine 10 (such as the input shaft 26, the output shaft and the fixed structure 24) may have any desired degree of stiffness or flexibility. By way of further example, any suitable arrangement of the bearings between rotating and stationary parts of the engine (for example between the input and output shafts from the gearbox and the fixed structures, such as the gearbox casing) may be used, and the disclosure is not limited to the exemplary arrangement of FIG. 2. For example, where the gearbox 30 has a star arrangement (described above), the skilled person would readily understand that the arrangement of output and support linkages and bearing locations would typically be different to that shown by way of example in FIG. 2.

[0105] Accordingly, the present disclosure extends to a gas turbine engine having any arrangement of gearbox styles (for example star or planetary), support structures, input and output shaft arrangement, and bearing locations.

[0106] Optionally, the gearbox may drive additional and/or alternative components (e.g. the intermediate pressure compressor and/or a booster compressor).

[0107] Other gas turbine engines to which the present disclosure may be applied may have alternative configurations. For example, such engines may have an alternative number of compressors and/or turbines and/or an alternative number of interconnecting shafts. By way of further example, the gas turbine engine shown in FIG. 1 has a split flow nozzle 18, 20 meaning that the flow through the bypass duct 22 has its own nozzle 18 that is separate to and radially outside the core exhaust nozzle 20. However, this is not limiting, and any aspect of the present disclosure may also apply to engines in which the flow through the bypass duct 22 and the flow through the core 11 are mixed, or combined, before (or upstream of) a single nozzle, which may be referred to as a mixed flow nozzle. One or both nozzles (whether mixed or split flow) may have a fixed or variable area. Whilst the described example relates to a turbofan engine, the disclosure may apply, for example, to any type of gas turbine engine, such as an open rotor (in which the fan stage is not surrounded by a nacelle) or turboprop engine, for example. In some arrangements, the gas turbine engine 10 may not comprise a gearbox 30.

[0108] The geometry of the gas turbine engine 10, and components thereof, is defined by a conventional axis system, comprising an axial direction (which is aligned with the rotational axis 9), a radial direction (in the bottom-to-top direction in FIG. 1), and a circumferential direction (perpendicular to the page in the FIG. 1 view). The axial, radial and circumferential directions are mutually perpendicular.

Abradable Seal Elements

[0109] FIG. 4 illustrates a turbine seal segment 41 for the high-pressure turbine 17. A plurality of arc-shaped sealing elements in the form of a turbine seal segment together form a substantially cylindrical seal segment ring which encases the rotating high pressure turbine blades 42. A small gap 44 is provided between the tips 46 of the turbine blades 42 and a radially inner surface 43 of the seal segment 41. The size of the gap 44 varies with time for various reasons, including variations in the temperatures of the turbine blades 42 and other components.

[0110] An open cell structure 48 is formed integrally with the turbine seal segment 41 in the region of its radially inner surface 43. The open cell structure 48 includes upstanding walls 50 which project radially inwards. The walls 50 define therebetween a plurality of open cells 54, the open cells 54 having generally circumferential bases 52. The open cells 54 are able to receive and support an abradable material.

[0111] FIGS. 5 to 7 illustrate an example abradable seal element 100 in more detail. The abradable seal element 100 includes a plurality of upstanding walls 102 which extend from a supporting substrate 104 (e.g. a supporting portion of the turbine seal segment 41 in FIG. 4). The walls 102 define therebetween a plurality of open cells 106. In this example, the open cells 106 defined by the walls 102 are generally cuboid. The walls 102 are made of a superalloy such as a nickel-based superalloy. The substrate 104 is also made of a superalloy such as nickel-based superalloy and may be monocrystalline. The open cells 106 are filled with an abradable material 108, such as a sintered powder material. It will be appreciated that the cells 106 are open cells in the sense that each cell has an open end (i.e. a radially inward open end which faces a turbine blade tip 46 in use) not covered by superalloy wall, where the abradable material filling is exposed to the surrounding atmosphere (as illustrated by the use of dashed lines in FIG. 7).

[0112] The skilled person will appreciate that many different wall arrangements, and therefore many different open cell shapes, are possible. For example, FIG. 8 illustrates an abradable seal element 200 in which a plurality of upstanding walls 202 are arranged in a zig-zag or saw-tooth pattern to define generally rhomboid-shaped, connected open cells 204. FIG. 9 illustrates an abradable seal element 300 in which a plurality of upstanding walls 302 are arranged in a diamond lattice pattern to define generally rhomboid-shaped, isolated open cells 304. FIG. 10 illustrates an abradable seal element 400 in which a single, continuous curvilinear upstanding wall 402 is arranged to define a plurality of open cells 404. FIG. 11 illustrates the repeating pattern of FIG. 10 in more detail.

[0113] Wall arrangements having few or no wall intersections or joins (for example, as seen in FIGS. 10 and 11) have been found to exhibit lower residual stresses and a reduced tendency towards cracking as compared to wall arrangements in which walls intersect or join with one another at many locations (for example, as seen in FIG. 9). Wall arrangements including a few or a single continuous curvilinear upstanding wall may therefore be beneficial.

[0114] Wall arrangements lacking enclosing lateral sidewalls (for example, where abradable material forms one or more lateral sides of the abradable sealing element, for example as seen in FIG. 10 or 11) have also been found to exhibit a reduced tendency to crack in use than wall arrangements including one or more lateral sidewalls which enclose the abradable material. Wall arrangements lacking enclosing lateral sidewalls may therefore be beneficial.

[0115] The skilled person will further appreciate that different wall and cell dimensions are possible. For example, each upstanding wall may have a wall height (i.e. measured in a direction locally perpendicular to the substrate) of up to about 10 mm and a wall width (i.e. measured in a direction locally parallel to the substrate) of from about 50 μm to about 1.2 mm. Adjacent walls may, on average, be spaced apart from one another by about 1 mm to about 2.5 mm. Each wall may extend away from the substrate in a direction which is substantially locally perpendicular to the substrate. Alternatively, one or more of the walls may be angled with respect to the substrate. For example, one or more of the wall may extend away from the substrate in a direction which is locally inclined at an oblique angle with respect to the substrate. The skilled person will appreciate that the relative geometry of the walls and the substrate is defined locally because the substrate may not be flat; for example, the substrate may have a curved surface.

[0116] As discussed hereinabove, the upstanding walls are formed from superalloy. The skilled person will appreciate that any suitable superalloy known in the art may be used. However, the superalloy selected is commonly a nickel-based superalloy. Suitable nickel-based superalloys include CM186, Rene 142, Haynes 214, Amdry 955, IN792 and Haynes 282, among others. The nickel-based superalloy will commonly include at least Ni and Al. One particularly suitable nickel-based superalloy has the composition defined in Table 1.

TABLE-US-00001 TABLE 1 Element Amount (weight %) Ni from 50 to 80 Co from 2 to 15 Cr from 3 to 10 W from 1 to 7 Re from 0 to 5 Al from 2 to 8 Ta from 4 to 8 Si from 0 to 1 Hf from 0 to 3 Mo from 0 to 3 Fe from 0 to 1 Ti from 0 to 1 Cu from 0 to 1 C from 0 to 0.04 B from 0 to 0.03

[0117] The substrate is also made of a superalloy. The skilled person will appreciate that any suitable superalloy known in the art may be used. However, the superalloy selected is commonly a nickel-based superalloy. Suitable nickel-based superalloys include CMSX-3, MarM247, CMSX-4, MM002, C1023, IN713LC and CM186, among others. The substrate may be a monocrystalline (i.e. single-crystal) nickel-based superalloy.

[0118] The skilled person will also appreciate that any suitable abradable material known in the art may be used to fill the open cells. The abradable material may be a ceramic, a metal or an intermetallic compound. For example, the abradable material may be selected from: yttria-stabilised zirconia (YSZ), alumina, nickel aluminide (Ni.sub.3Al), or any combination thereof. The abradable material may be particulate material. The abradable material may be a sintered material such as a sintered powder. The abradable material may be a ceramic, a metal or an intermetallic compound following sintering. For example, the abradable material may be or comprise nickel aluminide, formed by sintering nickel-aluminium powder. The abradable material may be porous or may be formed from porous or hollow powder (such as porous YZS, porous alumina or hollow NiAl powder (e.g. Metco 2101ZB, Metco 2110 or Metco 2501 available from OC Oerlikon)).

Manufacturing Method

[0119] Abradable sealing elements such as those illustrated in FIGS. 5 to 11 may be manufactured by (a) forming upstanding walls on a substrate, the upstanding walls defining open cells, and (b) filling the open cells with abradable material.

[0120] The upstanding walls may be formed on the substrate by additive-layer, powder-fed, laser-weld deposition (also known as laser weld deposition, laser metal deposition, laser blown powder, directed metal deposition or directed energy deposition).

[0121] FIG. 13 illustrates schematically powder-fed, laser-weld deposition apparatus 600. The apparatus 600 focuses a laser beam 602 onto a working region of a substrate 604. The apparatus 600 also supplies powdered material via powder feed tubes 606 to the working region of the substrate 604. The laser beam 602 and the powder feed tubes 606 are held static while the position and movement of the substrate 604 is controlled by a computer control system 608. As illustrated in FIG. 14, it is preferable to position the working region of the substrate 604 in a focal region 614 of the powder supply defined by the powdered material flow paths 616 determined by the nozzle 618 design, the target stand-off distance 620 and the powder focal distance 622. The focused laser beam 602 melts the powder supplied by the powder feed tubes 606, as well as a portion of the working region of the substrate 604, which mix and solidify when the laser beam 602 moves to a new position. A layer of fused material (i.e. a weld layer of material) is therefore formed on the substrate as it is passed through the laser beam 602 and flow of powdered material. The substrate may be passed by the laser multiple times in order to sequentially build up multiple overlying layers of fused material, thereby forming an upstanding wall extending from the substrate 604. The laser welding equipment and the working region of the substrate 604 may be enclosed in a sealed compartment 610 in which the atmosphere is controlled by a gas purifier 612 in order to avoid contamination of the deposited material. Alternatively, deposition may be carried out in an ambient atmosphere with the powder flow and melt pool shielded by the nozzle and the flow of carrier gas (such as argon).

[0122] Prior to deposition of the upstanding walls, the laser beam 602 may be scanned across the surface of the substrate 604, along paths where the walls are to be deposited, in order to remove contaminants, such as oxide films, from the substrate.

[0123] Following deposition of the upstanding walls using the laser-weld apparatus, the walls may be shaped using any suitable machining method, such as electrical discharge machining (EDM). In particular, machining may be used to reduce the height of the walls, render the height of the walls more uniform across the substrate, or otherwise adjust the profile of the walls. The surfaces of the walls and the open cells defined therebetween may be coated, for example by nickel plating.

[0124] The open cells may then be filled with the abradable material in powder form. The abradable material may then be sintered inside the open cells. A layer of less dense sinter material (i.e. a friable layer of sinter material) may then be removed by, e.g., manual dress, EDM or machining.

Optimisation of Wall Deposition

[0125] FIG. 15 illustrates, in cross-section, a wall 700 formed on a substrate 702 by the additive-layer, powder-fed, laser-weld deposition process described hereinabove. In particular, the wall 700 is formed by a plurality of overlying layers of fused material (hereinafter referred to as ‘weld layers’) 704. Each weld layer 704 is formed by a single pass of the substrate through the laser beam and powder supply during deposition. Following testing of the effects of varying different deposition parameters during the laser-weld deposition process, the inventors have found that the mechanical properties of the walls formed depend sensitively on the thickness of each of the weld layers. For example, thicker weld layers tend to result in increased microcracking during manufacture, with microcracks subsequently propagating through the structure when the abradable sealing element is used, particularly at high temperatures.

[0126] In particular, the inventors have found that it is preferable for each weld layer to have a thickness t (measured in a direction locally perpendicular to the surface of the substrate on which the wall is deposited) which is no greater than about 350 μm. When the thickness t of the weld layers exceeds about 350 μm, the inventors have found that the walls have a tendency to crack (i.e. undergo brittle failure) in use. In contrast, when the thickness t of the weld layers is less than about 350 μm, the mechanical properties (and particularly the high-temperature mechanical properties) of the walls are greatly improved.

[0127] Without wishing to be bound by theory, the inventors posit that reducing the weld layer thickness reduces residual stresses that are built up during deposition of the wall structure, resulting in reduced microcracking during manufacture and an increased resistance to temperature-induced cracking when the walls are exposed to the high temperatures found in the hot sections of gas turbine engines. The inventors have also found that a minimum weld layer thickness t of about 50 μm further improves the mechanical properties of the walls formed therefrom.

[0128] FIG. 19 illustrates the deposition method in a flow diagram. The method comprises: depositing a first layer of material onto the substrate (block 1100), wherein the layer of material has a thickness in a direction generally perpendicular to the substrate of from about 50 μm to about 350 μm; and depositing a second layer of material onto the first layer of material (block 1101), wherein the layer of material also has a thickness in a direction generally perpendicular to the substrate of from about 50 μm to about 350 μm. The method may comprise repeating block 1101, wherein each layer of material is deposited onto the layer of material deposited in the previous step, until a wall of predefined height is achieved.

[0129] It should be noted that the width w of each weld layer forming the wall structure need not be the same. For example, FIG. 16 illustrates, in cross-section, a wall 800 formed on a substrate 802 from a plurality of overlying weld layers 804 having varying weld layer widths w. For example, weld layer 804A has a width w.sub.A, while weld layer 804B has a width w.sub.B, wherein w.sub.A>w.sub.B. By depositing weld layers having different widths, it is possible vary the overall width of the wall with distance from the substrate. That is to say, it is possible to form walls having tapered width profiles. In addition, because the weld layer thicknesses are 350 μm or lower, it is possible to form gently tapered width profiles in which the width of the wall structure gently decreases with distance from the substrate. Wall structures having such gently tapered width profiles (i.e. in which there are only small changes in layer width between adjacent weld layers) are less prone to cracking in use than wall structures having tapered width profiles achieved through large step-changes in layer width (as occurs when thicker weld layers are used).

[0130] The inventors have found that a weld-layer thickness from about 50 μm to about 350 μm, thereby achieving the desired microstructure and reduction in residual stresses, can be obtained using the following laser-weld deposition parameters (where preferred values are indicated in parentheses):

[0131] Laser power: 20 to 500 Watts;

[0132] Laser scanning speed: 400 to 2000 mm/minute (e.g. about 1200 mm/minute);

[0133] Laser spot size: 50 to 1000 μm (e.g. about 200 to about 600 μm);

[0134] Powder feed rate: 0.25 to 10 g/minute (e.g. about 1.4 to about 3 g/minute);

[0135] Powder spot size: 0.1 to 3 mm (e.g. about 0.2 to about 0.5 mm).

[0136] Travel direction: alternating between layers.

[0137] Such laser-weld deposition parameters also result in a lower heat input and consequently a further reduction in residual stresses and microcracking.

[0138] The above parameters were determined using a CO.sub.2 laser, for example of the type TR1750/380 (Wegmann-Baasel Laser GmbH), but any other suitable type of laser (such as a solid state or fibre laser) may be used. The laser may be operated in a pulse mode, for example having a pulse frequency of about 1 kHz. The powder may be supplied to the substrate using a carrier gas, such as argon, for example supplied at a gas flow rate of about 1 to 5 l/minute, with a nozzle gas flow rate of about 5 to 12 l/minute.

[0139] FIG. 17 is an optical micrograph of a nickel-based superalloy wall 900 deposited on a substrate 902 by the laser-weld deposition method described hereinabove. The wall 900 has a visibly tapered width profile along a direction locally perpendicular to the substrate 902. The individual weld layers 904 are also visible in the image, as are weld interfaces 906 between each of the weld layers 904.

[0140] Although the above discussion relates to the deposition of nickel-based superalloy walls (i.e. using nickel-based superalloy powder in the laser-weld deposition process), the skilled person will appreciate that the methods described herein may be used to deposit walls of any type of material depositable by laser-weld deposition. In particular, the method may be used to deposit walls having a maximum wall thickness of about 1200 μm. The mechanical properties of such walls may be improved by controlling the weld layer thickness to be no greater than about 350 μm, and preferably from about 50 μm to about 350 μm.

[0141] The inventors have also developed a method for depositing walls (such as the upstanding walls of abradable sealing elements) on substrates using laser-weld deposition in circumstances where pre-existing neighbouring features on the substrate might otherwise be considered to hinder or prevent laser-weld deposition. For example, FIG. 18 illustrates deposition of a wall 1000 on a substrate 1002 by laser-weld deposition. A neighbouring structure 1004 is present on the substrate 1002. In conventional laser-weld deposition, the laser-weld apparatus 1006 and substrate 1002 are positioned such that the laser beam 1008 is substantially perpendicular to the surface of the substrate 1002 during the deposition process. In such a case, the minimum possible distance between the deposited layers forming the wall 1000 and the neighbouring structure 1004 is limited by the presence of the structure 1004, for example because the presence of the structure 1004 interferes with the nozzle of the apparatus 1006 reaching the correct location on the substrate 1002. However, the inventors have found that a wall 1000 may be deposited closer to the pre-existing structure 1004 by tilting the substrate 1002 such that the substrate is inclined at an oblique angle to the laser beam direction 1008 (as illustrated in FIG. 18). In addition, the inventors have found that, despite the inclined substrate 1002, it is still possible to deposit a wall 1000 which extends generally perpendicularly from the substrate 1002 by sequentially shifting the position of the substrate 1002 relative to the nozzle 1006 between deposition of each material layer. This method not only enables walls to be deposited in constrained spaces, but it also more generally enables walls to be deposited onto tilted or curved substrates.

[0142] The deposition methods discussed hereinabove may be used to form abradable seal elements on clean (i.e. new) substrates. Alternatively, these deposition methods may be used to form abradable seal elements on repurposed substrates. For example, these deposition methods may be used to retrofit abradable seal elements to existing gas turbine engine components, for example by depositing new abradable seal elements to the existing gas turbine engine components following removal of previous abradable seal elements (which may have been damaged in use).

Optimisation of Seal Design

[0143] As discussed hereinabove, abradable seal elements, such as those illustrated in FIGS. 5 to 11, are designed to be abraded by the rotating turbine blade tips 46 so as to obtain a good seal between the turbine seal segment 41 and the turbine blades 42. However, in order to maintain the seal around the turbine blades 42, it is important that the strength of the remaining, unabraded material is high and that an excessive amount of material is not abraded by the passage of the blades tips. It is also important that the abradable seal elements remain mechanically stable under the conditions (particularly, the temperature) found in gas turbine engines. In particular, it is important that brittle failure (i.e. cracking) of the upstanding walls is avoided, otherwise the abradable seal element may fail in use and require early maintenance or replacement.

[0144] Following testing of multiple abradable seal designs, the inventors have found that the high-temperature performance of the seal depends at least in part on the relative amounts of superalloy and abradable material present. In particular, the inventors have found improved behaviour when nickel-based superalloy constitutes from about 10% to about 50% of the total volume of the cellular region of the abradable seal element. The inventors have also found even further improved behaviour when nickel-based superalloy constitutes from about 25% to about 35% of the total volume of the cellular region of the abradable seal element. In particular, optimisation of the relative amounts of superalloy and abradable material enables the required tribological, thermophysical and mechanical properties for an abradable seal to be achieved while ensuring that the deposited structures do not undergo cracking during use at high temperatures.

[0145] The skilled person will appreciate that the cellular region of the abradable seal element is the region of the abradable seal element formed by the superalloy upstanding walls and the abradable material filling the open cells defined therebetween. The total volume of the cellular region is the total geometric volume of the cellular region, i.e. as defined by the outer surfaces of bounding upstanding walls and an outer surface of the abradable material filling each open cell. For example, FIG. 12 shows a micrograph of a cross-section through a portion of an abradable seal 500 in which superalloy upstanding walls 502, abradable material 504 and substrate 506 are indicated. The volume of upstanding wall in the cellular region may be estimated by measuring and comparing the area of upstanding wall and the total area of the cellular region visible in the image. The total area of the cellular region is the geometric area of the image filled by upstanding wall 502 and abradable material 504. Spaces between individual particles of abradable material 504 are included when the area of the abradable material 504 is determined, that is to say that the measured area of abradable material 504 is equivalent to the geometric area of the portion of each open cell filled with abradable material. In examples in which a cell is entirely filled with abradable material (ignoring the presence of any spaces between individual particles of abradable material), the volume of abradable material in the cell is taken to be the total geometric volume of the cell (i.e. the volume defined by the interior surfaces of the walls bounding the cell and a flat plane drawn across the open end of the cell which contact the bounding walls on each side of the cell). The area of the substrate 506 is not taken into account in the calculation.

[0146] Since the total area of the cellular region is formed by areas of superalloy wall and areas of abradable material, when the volume of superalloy is from about 10% to about 50% of the total volume of the cellular region, the volume of abradable material is generally about 50% to about 90% of the total volume of the cellular region. Similarly, when the volume of superalloy is from about 25% to about 35% of the total volume of the cellular region, the volume of abradable material is generally about 65 to about 75% of the total volume of the cellular region. That is to say, the volume of superalloy wall and the volume of abradable material generally adds up to the total volume of the cellular region.

[0147] The inventors have found that these optimal volume ratios of nickel-based superalloy to abradable material are independent of the geometry (i.e. the cell wall arrangement and cell shape) of the abradable seal element. These results are based on tests carried out for abradable seal elements in which the walls are formed from a nickel-based superalloy having the composition shown in Table 1 and an abradable material formed by sintering a hollow NiAl powder. However, the inventors have found that the optimal volume ratio is substantially independent of the particular nickel-based superalloy or abradable material chosen.

EXAMPLES

Example 1

[0148] An abradable seal element was manufactured by (a) using additive-layer, powder-fed, laser-weld deposition to form a plurality of nickel-based superalloy wall structures defining open cells on a surface of a substrate and (b) sintering an abradable material within the open cells. The additive-layer, powder-fed, laser-weld deposition parameters were set such that the wall structures included thick weld layers having layer thicknesses greater than 350 μm and the dimensions of each wall structure were selected such that nickel-based superalloy constituted from about 10% to about 50 of the total volume of the abradable seal element following filling of the open cells with abradable material.

[0149] A section through the abradable seal element, in a plane perpendicular to the surface of the substrate, was ground and polished according to standard metallurgical sampling procedures and imaged in an optical microscope. FIG. 20 shows an optical micrograph of the section. At locations in the micrograph labelled C, horizontal cracking was observed.

Example 2

[0150] An abradable seal element was manufactured by (a) using additive-layer, powder-fed, laser-weld deposition to form a plurality of nickel-based superalloy wall structures defining open cells on a surface of a substrate and (b) sintering an abradable material within the open cells. The additive-layer, powder-fed, laser-weld deposition parameters were set such that each wall structure was formed from weld layers having layer thicknesses no greater than 350 μm and the dimensions of each wall structure were selected such that nickel-based superalloy constituted from about 10% to about 50% of the total volume of the abradable seal element following filling of the open cells with abradable material.

[0151] A section through the abradable seal element, in a plane perpendicular to the surface of the substrate, was ground, polished and etched according to standard metallurgical sampling procedures and imaged in an optical microscope. FIG. 21 shows an optical micrograph of the section. No horizontal cracking was observed.