Cold spray process for seal applications

摘要

A method of forming an interstage seal including removing a diaphragm seal box ( 14 ) from a gas turbine compressor assembly ( 10 ) and removing a labyrinth sealing member ( 12 ) from the diaphragm seal box ( 14 ). An abradable material layer ( 34 ) may be deposited on the diaphragm seal box ( 14 ). A spray gun may be mounted in relation to an engine disk ( 16 ) of the gas turbine compressor assembly ( 10 ) for cold-spraying a quantity of particles toward the engine disk ( 16 ). The particles may be sprayed at a velocity sufficiently high to cause at least a portion of the quantity of particles to adhere to the engine disk ( 16 ). The spray gun may be controlled to deposit a quantity of particles on the compressor disk ( 16 ) to form a geometry ( 32 ) that will abrade the abradable material layer ( 34 ) during operation of the gas turbine compressor assembly ( 10 ). The geometry ( 32 ) abrading the abradable material layer ( 34 ) forms an interstage seal. Rotation of the engine disk ( 16 ) within the gas turbine compressor assembly ( 10 ) may be controlled during the step of controlling the spray gun. The diaphragm seal box ( 14 ) may be reinstalled within the gas turbine compressor assembly ( 10 ) so that the geometry ( 32 ) aligns with the abradable material layer ( 34 ).