Gas turbine honeycomb seal

Abstract

A honeycomb seal which is manufactured by powder metallurgical injection molding is disclosed. The honeycomb seal is composed preferably of several segments. Each segment is embodied as a single piece and has a base element as well as honeycomb elements that are embodied as a single piece with the base element.

1 . A method for manufacturing a honeycomb seal for sealing a radial gap between a rotor and a stator of a gas turbine, comprising the step of manufacturing the honeycomb seal by powder metallurgical injection molding. 
   
   
       2 . The method of  claim 1 , further comprising the steps of:
 subjecting a molded honeycomb seal to a releasing process to release a binding agent used in the powder metallurgical injection molding process; and   compressing the molded honeycomb seal after the releasing process via a sintering process.   
   
   
       3 . The method of  claim 1 , further comprising the steps of forming the honeycomb seal in a plurality of segments wherein each segment is formed as a single piece that includes a base element and honeycomb elements and further wherein the base element bears the honeycomb elements. 
   
   
       4 . The method of  claim 3 , further comprising the steps of connecting the plurality of segments to a supporting structure and manufacturing the plurality of segments and the supporting structure of different materials. 
   
   
       5 . The method of  claim 4 , further comprising the steps of connecting a guide section of the base element to the supporting structure and interlocking adjacent segments with each other by engaging a projection of a first segment with a recess of an adjacent second segment. 
   
   
       6 . A method of forming a honeycomb seal, in particular to seal a radial gap between a rotor and stator of a gas turbine, comprising the step of forming a base element of the honeycomb seal with honeycomb elements of the seal as a single piece. 
   
   
       7 . The method of  claim 6 , further comprising the steps of:
 forming the base element in a first material; and   forming the honeycomb elements in a second material.   
   
   
       8 . The method of  claim 6 , further comprising the steps of:
 forming the honeycomb seal in a plurality of segments, wherein each segment includes a base element and honeycomb elements;   forming a first segment of the plurality of segments in a first material; and   forming a second segment of the plurality of segments in a second material.   
   
   
       9 . The method of  claim 6 , further comprising the steps of:
 forming the honeycomb seal in a plurality of segments, wherein each segment includes a base element and honeycomb elements;   forming a first segment of the plurality of segments in a first physical geometry; and   forming a second segment of the plurality of segments in a second physical geometry.