Patent Description:
<CIT> to Miller discloses a replacement nozzle for gas turbine engine. A replacement nozzle is cast to include replacement vanes extending between a replacement outer band and an inner web, with the replacement outer band and vanes conforming with the original outer band and vanes. The new web is configured differently than the old inner band and includes a tie bar. The inner band is machined to form vane seats. The web is machined to form plinths atop the tie bar at each of the replacement vanes. The plinths and tie bar are assembled through the vane seats and bonded to the machined inner band to collectively form the repaired turbine nozzle.

Further, <CIT> discloses methods and apparatus for fabricating a turbine nozzle assembly including at least two turbine nozzle singlets. Each singlet includes inner and outer bands and a vane extending therebetween. The vane includes sidewalls coupled together at a leading edge and a trailing edge. The apparatus comprises a fixture, and at least two support members extending from the fixture. Each support member has first and second abutment surfaces, wherein a first of the at least two support members contacts at least one of the leading and trailing edges of a first of the vanes. At least two locating features extend from the fixture, wherein a first of the locating features contacts one of the first and second sidewalls of the first vane. At least two biasing members are coupled to the fixture, wherein a first of the biasing members biases the first vane against the first locating feature.

In accordance with the present invention, a device for securing a gas turbine nozzle segment as set forth in Claim <NUM> is provided. Further embodiments of the invention are inter alia disclosed in the dependent claims. In general, this disclosure describes systems and methods related to devices and methods for sealing nozzle ports during manufacturing and machining. The systems, methods and devices of this disclosure each have several innovative aspects, no single one of which is solely responsible for the desirable attributes disclosed herein.

One aspect of the disclosure provides a device for securing a gas turbine nozzle segment and sealing one or more cooling cavities of the gas turbine nozzle segment during manufacturing. The device can have a support assembly for receiving a nozzle segment having at least one cooling cavity. The device can have a first clamp assembly configured to secure a first portion of the nozzle segment to the support assembly, the first clamp assembly having a first clamp arm, and a first tightening assembly coupling the first clamp arm to the support assembly. The device can have a first port seal assembly. The port seal assembly can have a first seal body hingeably attached to the support assembly. The port seal assembly can have at least one sealing member coupled to the first seal body and configured to interact with and seal the corresponding one or more cooling cavities.

Another aspect of the disclosure provides a device for sealing one or more cooling cavities of a gas turbine nozzle segment during manufacturing. The device can have a support assembly for receiving a nozzle segment having at least one cooling cavity. The device can have a first clamp assembly configured to secure a first portion of the nozzle segment to the support assembly. The first clamp assembly can have a first clamp arm. The first clamp assembly can have a first hinge assembly. The first clamp assembly can have a first port seal coupled to the first clamp arm by the first hinge assembly. The first port seal can have at least one sealing member configured to interact with the corresponding one or more cooling cavities. The first clamp assembly can have a first tightening assembly coupling the first clamp arm to the support assembly and allowing the first clamp assembly to selectively move toward and away from a center of the support assembly. The device can have a second clamp assembly disposed on a second side of the support assembly and configured to secure a second portion of the nozzle segment. The second clamp assembly can have a second clamp arm. The second clamp assembly can have a second tightening assembly coupling the second clamp arm to the support assembly and allowing the second clamp assembly to selectively move toward and away from the center of the support assembly, opposite the first clamp assembly.

Another aspect of the disclosure provides a device for sealing one or more cooling cavities of a gas turbine nozzle segment during manufacturing. The device can have a support assembly for receiving a nozzle segment having at least one cooling cavity. The device can have a first clamp assembly configured to secure a first portion of the nozzle segment, the first clamp assembly having a first clamp arm, and a first securing assembly coupling the first clamp arm to the support assembly. The device can have a first port seal assembly. The first port seal assembly can have a seal body. The first port seal assembly can have at least one sealing member coupled to the seal body and configured to interact with and seal the corresponding one or more cooling cavities. The first port seal assembly can have a seal leg coupled to the seal body and extending away from the seal body opposite the at least one sealing member, the seal leg having a seal leg axis. The first port seal assembly can have a first wall coupled to the support assembly having an aperture to slidably receive the seal leg of the first port seal assembly.

Other features and advantages of the present disclosure should be apparent from the following description which illustrates, by way of example, aspects of the disclosure.

The details of embodiments of the present disclosure, both as to their structure and operation, may be gleaned in part by study of the accompanying drawings, in which like reference numerals refer to like parts, and in which:.

The detailed description set forth below, in connection with the accompanying drawings, is intended as a description of various embodiments. The detailed description includes specific details for the purpose of providing a thorough understanding of the embodiments as set out in the appended claims. In some instances, well-known structures and components are shown in simplified form for brevity of description.

<FIG> is a schematic illustration of an exemplary gas turbine engine. Some of the surfaces have been left out or exaggerated (here and in other figures) for clarity and ease of explanation. Also, the disclosure may reference a forward and an aft direction. Generally, all references to "forward" and "aft" are associated with the flow direction of primary air <NUM> (i.e., air used in the combustion process), unless specified otherwise. For example, forward is "upstream" relative to primary air flow, and aft is "downstream" relative to primary air flow.

In addition, the disclosure may generally reference a center axis <NUM> of rotation of the gas turbine engine, which may be generally defined by the longitudinal axis of its shaft <NUM> (supported by a plurality of bearing assemblies <NUM>). The center axis <NUM> may be common to or shared with various other engine concentric components. All references to radial, axial, and circumferential directions and measures refer to center axis <NUM>, unless specified otherwise, and terms such as "inner" and "outer" generally indicate a lesser or greater radial distance from center axis <NUM>, wherein a radial <NUM> may be in any direction perpendicular and radiating outward from center axis <NUM>.

A gas turbine engine <NUM> includes an inlet <NUM>, a shaft <NUM>, a compressor <NUM>, a combustor <NUM>, a turbine <NUM>, an exhaust <NUM>, and a power output coupling <NUM>. The gas turbine engine <NUM> may have a single shaft or a dual shaft configuration.

The compressor <NUM> includes a compressor rotor assembly <NUM>, compressor stationary vanes (stators) <NUM>, and inlet guide vanes <NUM>. The compressor rotor assembly <NUM> mechanically couples to shaft <NUM>. As illustrated, the compressor rotor assembly <NUM> is an axial flow rotor assembly. The compressor rotor assembly <NUM> includes one or more compressor disk assemblies <NUM>. Each compressor disk assembly <NUM> includes a compressor rotor disk that is circumferentially populated with compressor rotor blades. Stators <NUM> axially follow each of the compressor disk assemblies <NUM>. Each compressor disk assembly <NUM> paired with the adjacent stators <NUM> that follow the compressor disk assembly <NUM> is considered a compressor stage. Compressor <NUM> includes multiple compressor stages. Inlet guide vanes <NUM> axially precede the compressor stages at the beginning of an annular flow path <NUM> through the gas turbine engine <NUM>.

The turbine <NUM> includes a turbine rotor assembly <NUM> and turbine nozzles <NUM> within a turbine housing <NUM>. The turbine rotor assembly <NUM> mechanically couples to the shaft <NUM>. In the embodiment illustrated, the turbine rotor assembly <NUM> is an axial flow rotor assembly. The turbine rotor assembly <NUM> includes one or more turbine disk assemblies <NUM>. Each turbine disk assembly <NUM> includes a turbine disk that is circumferentially populated with turbine blades. Turbine nozzles <NUM> axially precede each of the turbine disk assemblies <NUM>. Each turbine disk assembly <NUM> paired with the adjacent turbine nozzles <NUM> that precede the turbine disk assembly <NUM> is considered a turbine stage. Turbine <NUM> includes multiple turbine stages.

The exhaust <NUM> includes an exhaust diffuser <NUM> and an exhaust collector <NUM> that can collect exhaust gas <NUM>. The power output coupling <NUM> may be located at an end of shaft <NUM>.

<FIG> is a perspective view of a turbine nozzle of the gas turbine engine of <FIG>. The gas turbine engine <NUM> can have more than one nozzle <NUM> as shown in <FIG>. The turbine nozzle(s) <NUM> can alternate with the turbine disk assemblies <NUM>.

Each nozzle <NUM> can have a plurality of turbine nozzle segments (nozzle segments) <NUM> that can be assembled radially about the center axis <NUM> to form the complete assembly of the turbine nozzle <NUM>. One turbine nozzle segment <NUM> is shown exploded from the turbine nozzle <NUM> in <FIG>.

The nozzle segment <NUM> includes upper shroud <NUM>, lower shroud <NUM>, a first airfoil <NUM>, and a second airfoil <NUM>. In other embodiments, nozzle segment <NUM> can include more or fewer airfoils, such as one airfoil, three airfoils, or four airfoils. Upper shroud <NUM> may be located adjacent and radially inward from turbine housing <NUM> when nozzle segment <NUM> is installed in gas turbine engine <NUM>. Upper shroud <NUM> includes upper endwall <NUM>. Upper endwall <NUM> may be a portion of an annular shape, such as a sector. For example, the sector may be a sector of a toroid (toroidal sector) or a sector of a hollow cylinder. The toroidal shape may be defined by a cross-section with an inner edge including a convex shape. Multiple upper endwalls <NUM> are arranged to form the annular shape, such as a toroid, and to define the radially outer surface of the annular flow path <NUM> through a turbine nozzle <NUM>. Upper endwall <NUM> may be coaxial to center axis <NUM> when installed in the gas turbine engine <NUM>.

Upper shroud <NUM> may also include upper forward rail <NUM> and upper aft rail <NUM>. Upper forward rail <NUM> extends radially outward from upper endwall <NUM>. In the embodiment illustrated in <FIG>, upper forward rail <NUM> extends from upper endwall <NUM> at an axial end of upper endwall <NUM>. In other embodiments, upper forward rail <NUM> extends from upper endwall <NUM> near an axial end of upper endwall <NUM> and may be adjacent to the axial end of upper endwall <NUM>. Upper forward rail <NUM> may include a lip, protrusion or other features that may be used to secure nozzle segment <NUM> to turbine housing <NUM>.

Upper aft rail <NUM> may also extend radially outward from upper endwall <NUM>. In the embodiment illustrated in <FIG>, upper aft rail <NUM> is 'L' shaped, with a first portion extending radially outward from the axial end of upper endwall <NUM> opposite the location of upper forward rail <NUM>, and a second portion extending in the direction opposite the location of upper forward rail <NUM> extending axially beyond upper endwall <NUM>. In other embodiments, upper aft rail <NUM> includes other shapes and may be located near the axial end of upper endwall <NUM> opposite the location of upper forward rail <NUM> and may be adjacent to the axial end of upper endwall <NUM> opposite the location of upper forward rail <NUM>. Upper aft rail <NUM> may also include other features that may be used to secure nozzle segment <NUM> to turbine housing <NUM>.

Lower shroud <NUM> is located radially inward from upper shroud <NUM>. Lower shroud <NUM> may also be located adjacent and radially outward from turbine diaphragm <NUM> (<FIG>) when nozzle segment <NUM> is installed in gas turbine engine <NUM>. Lower shroud <NUM> includes lower endwall <NUM>. Lower endwall <NUM> is located radially inward from upper endwall <NUM>. Lower endwall <NUM> may be a portion of an annular shape, such as a sector. For example, the sector may be a portion of a nozzle ring. Multiple lower endwalls <NUM> are arranged to form the annular shape, such as a toroid, and to define the radially inner surface of the flow path through a turbine nozzle <NUM>. Lower endwall <NUM> may be coaxial to upper endwall <NUM> and center axis <NUM> when installed in the gas turbine engine <NUM>.

Lower shroud <NUM> may also include lower forward rail <NUM> and lower aft rail <NUM>. Lower forward rail <NUM> extends radially inward from lower endwall <NUM>. In the embodiment illustrated in <FIG>, lower forward rail <NUM> extends from lower endwall <NUM> at an axial end of lower endwall <NUM>. In other embodiments, lower forward rail <NUM> extends from lower endwall <NUM> near an axial end of lower endwall <NUM> and may be adjacent lower endwall <NUM> near the axial end of lower endwall <NUM>. Lower forward rail <NUM> may include a lip, protrusion or other features that may be used to secure nozzle segment <NUM> to turbine diaphragm <NUM>.

The lower aft rail <NUM> may also extend radially inward from lower endwall <NUM>. In the embodiment illustrated in <FIG>, lower aft rail <NUM> extends from lower endwall <NUM> near the axial end of lower endwall <NUM> opposite the location of lower forward rail <NUM> and may be adjacent the axial end of lower endwall <NUM> opposite the location of lower forward rail <NUM>. In other embodiments, lower aft rail <NUM> extends from the axial end of lower endwall <NUM> opposite the location of lower forward rail <NUM>. Lower aft rail <NUM> may also include a lip, protrusion or other features that may be used to secure nozzle segment <NUM> to turbine diaphragm <NUM>.

The airfoil <NUM> extends between the upper endwall <NUM> and the lower endwall <NUM>. The airfoil <NUM> includes the leading edge <NUM>, the trailing edge <NUM>, the pressure side wall <NUM>, and the suction side wall <NUM>. The leading edge <NUM> extends from the upper endwall <NUM> to the lower endwall <NUM> at the most upstream axial location where highest curvature is present. The leading edge <NUM> may be located near the upper forward rail <NUM> and the lower forward rail <NUM>. The trailing edge <NUM> may extend from the upper endwall <NUM> axially offset from and distal to the leading edge <NUM>, adjacent the axial end of the upper endwall <NUM> opposite the location of the leading edge <NUM> and from the lower endwall <NUM> adjacent the axial end of the upper endwall <NUM> opposite and axially distal to the location of the leading edge <NUM>. When the nozzle segment <NUM> is installed in the gas turbine engine <NUM>, the leading edge <NUM>, the upper forward rail <NUM>, and the lower forward rail <NUM> may be located axially forward and upstream of the trailing edge <NUM>, the upper aft rail <NUM>, and the lower aft rail <NUM>. The leading edge <NUM> may be the point at the upstream end of the airfoil <NUM> with the maximum curvature and the trailing edge <NUM> may be the point at the downstream end of the airfoil <NUM> with maximum curvature. In the embodiment illustrated in <FIG>, the nozzle segment <NUM> is part of the first stage turbine nozzle <NUM> adjacent the combustion chamber <NUM>. In other embodiments, the nozzle segment <NUM> is located within a turbine nozzle <NUM> of another stage.

The pressure side wall <NUM> may span or extend from the leading edge <NUM> to the trailing edge <NUM> and from the upper endwall <NUM> to the lower endwall <NUM>. The pressure side wall <NUM> may include a concave shape. The suction side wall <NUM> may also span or extend from the leading edge <NUM> to the trailing edge <NUM> and from the upper endwall <NUM> to the lower endwall <NUM>. The suction side wall <NUM> may include a convex shape. The leading edge <NUM>, the trailing edge <NUM>, the pressure side wall <NUM> and the suction side wall <NUM> may contain a cooling cavity <NUM> (partially shown in <FIG>) there between.

The airfoil <NUM> can have multiple cooling holes or apertures, such as leading edge cooling apertures <NUM>. The leading edge cooling apertures <NUM> can be pressure side cooling apertures and/or showerhead cooling apertures. The airfoil <NUM> can also have trailing edge cooling apertures <NUM>. Each cooling hole or cooling aperture <NUM>, <NUM> may be a channel extending through a wall of the airfoil <NUM>. Each set of cooling apertures <NUM> may be grouped together in a pattern, such as in a row or in a column.

In the embodiment illustrated in <FIG>, the nozzle segment <NUM> includes second airfoil <NUM>. Second airfoil <NUM> may be circumferentially offset from airfoil <NUM>. Second airfoil <NUM> may include the same or similar features as airfoil <NUM> including second leading edge <NUM> and a second trailing edge (not shown), and various cooling apertures <NUM>, <NUM>. The suction sidewall and pressure sidewall of the airfoil <NUM> are not labeled in <FIG>.

The various components of nozzle segment <NUM> including upper shroud <NUM>, lower shroud <NUM>, airfoil <NUM>, and second airfoil <NUM> may be integrally cast or metallurgically bonded to form a unitary, one piece assembly thereof.

<FIG> is a perspective view of a device for sealing the turbine nozzle segment of <FIG> during manufacturing. The nozzle segment <NUM> is shown in dashed lines indicating how it would be inserted in to the device. In one or more manufacturing, machining, or milling processes, ports, channels, or other cuts may be formed into portions of the nozzle segment <NUM>. For example, the upper aft rail <NUM> or the lower aft rail <NUM> may require adjustments or further machining following the initial casting or formation of the component (e.g., the nozzle segment <NUM>). Accordingly, small particles, dust, metal flakes, etc., that result from such processes may be introduced into the cooling cavity <NUM> within the airfoil <NUM>, <NUM> for example. The particles introduced may be byproducts of the milling or machining processes and thus can be quite small. These small particles can be caught or lodged within the cooling cavity <NUM> and obstruct the cooling apertures (e.g., the cooling apertures <NUM>, <NUM> shown in <FIG>). For example, particles smaller than approximately <NUM> microns may be small enough to pass through the nozzle segment <NUM> and the cooling apertures. However, particles larger than <NUM> microns may be large enough to obstruct the cooling apertures.

A device <NUM> can receive and secure the nozzle segment <NUM> and prevent the metal flakes, dust, or other small particles from entering and clogging the cooling cavity <NUM> and any holes or other perforations in the nozzle segment <NUM>.

The device <NUM> can have a platform <NUM>. The platform <NUM> can generally lie in a horizontal plane. The horizontal plane as shown is the x,y plane. The platform <NUM> can have a nozzle segment support assembly (support assembly) <NUM>. The support assembly <NUM> can have a substantially flat surface to receive the nozzle segment <NUM>. The support assembly <NUM> can have one or more grooves <NUM> or other features to accommodate the upper aft rail <NUM> (<FIG>), for example. The grooves <NUM> can be oriented laterally across the support assembly <NUM> running generally parallel to the upper aft rail <NUM> or the lower aft rail <NUM>. The support assembly <NUM> can be coupled to the platform <NUM> by fasteners, bolts, or other applicable hardware.

The support assembly <NUM> can be coupled to a first clamp assembly <NUM> and a second clamp assembly <NUM>. The first clamp assembly <NUM> and the second clamp assembly <NUM> can receive and secure the nozzle segment <NUM> (shown in dashed lines). The groove(s) <NUM> can also be oriented horizontally (e.g., x-axis) to run between first clamp assembly <NUM> and the second clamp assembly <NUM>.

The first clamp assembly <NUM> can further include a port seal assembly (port seal) <NUM>. The port seal <NUM> can have one or more sealing members <NUM> coupled to a seal body <NUM>. Two sealing members <NUM> are shown, labeled individually as sealing member 486a and sealing member 486b. Each of the sealing members <NUM> can have a polymer structure sized to be received within an associated cooling cavity <NUM> within the nozzle segment <NUM>. In some embodiments the sealing members <NUM> can have a foil shape. The sealing members <NUM> can be formed from any elastomeric compound. In some embodiments, it may be a urethane compound. In some other embodiments, the sealing members may be formed of a rigid material, such as a <NUM>-D printed metallic construction. Any of the sealing members disclosed herein can be formed in the above-described ways.

The first clamp assembly <NUM> and the second clamp assembly <NUM> can generally move in the horizontal (x,y) plane, or toward and away from the nozzle segment <NUM>.

<FIG> is a top plan view of the device of <FIG>. The device <NUM> can receive the nozzle segment <NUM> (shown in dashed lines) and secure it in place on the platform <NUM> for further machining, for example. The second clamp assembly <NUM> can have a clamp arm <NUM> that can move in a (horizontal) direction indicated by the arrow (direction) <NUM>. The clamp arm <NUM> can then be secured in place by a tightening assembly <NUM>. The tightening assembly <NUM> can be for example a threaded post or bolt and associated nut and washer as depicted. Other securing means such as a latch, lever, fastener, or other friction-based components are also possible. The tightening assembly <NUM> can further have a spring <NUM> or other elastic member configured to raise or lift the clamp arm <NUM> away from the nozzle segment when the tightening assembly <NUM> is loosened. The tightening assembly <NUM> (as with other embodiments of securing or tightening assemblies disclosed herein) can also have the spring <NUM>, even though not specifically stated. Therefore the tightening assemblies or the securing assemblies disclosed herein can allow the corresponding clamp arm (or hinge support arm as needed) to selectively move toward and away from nozzle segment <NUM> (e.g., the center of the support assembly <NUM>). This can be done by loosening or tightening the associated hardware.

The first clamp assembly <NUM> can have a hinge assembly <NUM>. The hinge assembly <NUM> can have a hinge support member <NUM>, or clamp arm, coupled to a hinge arm <NUM> at a pivot point <NUM>. The hinge arm <NUM> can also be referred to as an actuation arm. The hinge assembly <NUM> can include a pin extending through the hinge arm <NUM> and the hinge support member <NUM> coincident with the pivot point <NUM>. The pin can generally extend along the x-axis shown in <FIG>. Thus the hinge arm <NUM> can pivot about point <NUM> in the y,z plane (<FIG>). For example, the hinge assembly <NUM> allows the port seal <NUM> to rotate in an arcuate path (e.g., direction <NUM> of <FIG>) substantially perpendicular to the support assembly <NUM>.

The hinge assembly <NUM> (and the first clamp assembly <NUM> more generally) can further be adjusted in the (e.g., horizontal) direction indicated by an arrow (direction) <NUM>. The hinge support member <NUM> can slide in the direction <NUM> and be secured in place by a tightening assembly <NUM>. The tightening assembly <NUM> can be similar to the tightening assembly <NUM>. The tightening assembly <NUM> can include a threaded post or bolt and corresponding nut, or other friction-based components, for example, to secure the first clamp assembly <NUM> in place.

<FIG> is a cross section of the device of <FIG>, taken along line <NUM> - <NUM>. The cross-section of <FIG> depicts the interior structure of the nozzle segment <NUM> and the cooling cavity <NUM> within the nozzle segment <NUM>. When secured in place, the sealing member 486a a can plug the opening of the cooling cavity <NUM> on one side of the nozzle segment <NUM>.

The nozzle segment <NUM> can be secured in place on the support assembly <NUM> using the first clamp assembly <NUM> and the second clamp assembly <NUM>. On one side of the nozzle segment <NUM>, the hinge arm <NUM> of the hinge assembly <NUM> and the first clamp assembly <NUM>, can be rotated about the pivot point <NUM> (e.g., on the x-axis and in the y, z plane) toward the nozzle segment <NUM> and into place. The first clamping assembly <NUM> and by extension, the sealing members <NUM> can be slid in toward the nozzle segment (in direction <NUM>) such that the sealing members <NUM> are inserted into the cooling cavity <NUM>. The sealing members <NUM> can have an external shape similar to the shape of the opening of the cooling cavity <NUM> and thus seal the opening of the cooling cavity <NUM>. This can prevent particulate matter from various machining processes from entering the cooling cavity <NUM> and clogging the cooling apertures <NUM> or the trailing edge cooling apertures <NUM>.

In addition, a clamp arm end <NUM> that extends horizontally from the hinge support member <NUM>, can contact a portion of the nozzle segment <NUM> such as the upper aft rail <NUM> to hold the nozzle segment <NUM> in place.

The opposite portion of the nozzle segment <NUM> can be secured in place on the support assembly <NUM> by sliding the clamp arm <NUM> horizontally toward the nozzle segment <NUM> (direction <NUM>) and tightening the tightening assembly <NUM> to prevent the clamp arm <NUM> from sliding. The clamp arm <NUM> can have a clamp arm end <NUM> configured to contact or engage with a portion of the nozzle segment <NUM> such as the lower aft rail <NUM> (or other relevant portion of the nozzle segment <NUM>) to hold the nozzle segment <NUM> in place. The clamp arm end <NUM> can have a curved or hook shape allowing more precise clamping or fitting for the nozzle segment <NUM>.

<FIG> is a cross section of the device of <FIG> taken along the line <NUM>-<NUM>. To release the nozzle segment <NUM> from the first clamp assembly <NUM>, the tightening assembly <NUM> can be loosened. The hinge support member <NUM> and thus the clamp arm end <NUM> can be retracted from the upper aft rail <NUM> in a direction indicated by an arrow (direction) <NUM>. At the same time, the hinge arm <NUM> and the sealing members <NUM> (486b, as shown) can be rotated about the pivot point <NUM> (e.g., in the x-axis) in the vertical plane away from the nozzle segment <NUM> in a direction indicated by an arrow (direction) <NUM>.

<FIG> is a perspective view of another embodiment a device for sealing the turbine nozzle segment of <FIG> during manufacturing. A device <NUM> can be used to seal the turbine nozzle segment <NUM> during manufacturing similar to the embodiments described in the foregoing. In some embodiments, the device <NUM> can be similar to the device <NUM> (<FIG>), having many of the same features. For example, the device <NUM> can have the platform <NUM>, the support assembly <NUM>, and the first clamp assembly <NUM> to name a few.

In some embodiments, the device <NUM> can have a second clamp assembly <NUM>. The second clamp assembly <NUM> can have a hinge support member, or hinge support <NUM>. The second clamp assembly <NUM> can have a hinge arm <NUM> rotatably coupled to the hinge support <NUM> at a hinge assembly <NUM>. The hinge arm <NUM> can also be referred to as an actuation arm. The hinge arm <NUM> can have a hinge arm end <NUM> distal to the hinge assembly <NUM>. The hinge arm end <NUM> can be coupled to a port seal <NUM>. The port seal <NUM> can be similar to the port seal <NUM> (<FIG>). The port seal <NUM> can have a port seal platform <NUM>, or seal body, having one or more sealing members <NUM> (shown as sealing members 706a, 706b). The sealing members <NUM> can be similar to the sealing members <NUM>. The sealing members <NUM> can engage with the cooling cavity <NUM> on an opposite side of the nozzle segment <NUM> from the sealing members <NUM>. The sealing members <NUM> can have an elastic, polymer, or elastomer construction and a profile similar to that of the cooling cavity so as to form an airtight seal with the cooling cavity. In some examples, the sealing members <NUM> function similar to a cork in a bottle. The sealing members <NUM> can have a profile similar to that of the opening of the cooling cavity <NUM>, such as an airfoil.

The hinge assembly can have a pin <NUM> that allows the hinge arm <NUM> and thus the sealing members <NUM>, to rotate about the x-axis and the pin <NUM> and in the y,z plane. This can allow the port seal <NUM> to be rotated away from the support assembly <NUM> and allow insertion of the nozzle segment <NUM>. The port seal <NUM> can thus rotate in an arcuate path toward and away from the secured nozzle segment <NUM>. The arcuate path may line in a substantially vertical plane.

The second clamp assembly <NUM> can also have a tightening assembly <NUM>. The tightening assembly <NUM> can be similar to the tightening assemblies <NUM>, <NUM>. The tightening assembly <NUM> can be loosened to allow the hinge support arm <NUM> and thus the port seal <NUM> to slide horizontally (e.g., along the y-axis) in the direction of an arrow (direction) <NUM>. Similar to the tightening assemblies <NUM>, <NUM>, the tightening assembly <NUM> can allow adjustment of the port seal <NUM> toward or away from the nozzle segment <NUM>.

In some embodiments, the second clamp assembly <NUM> and the hinge support arm <NUM> can have a clamp arm end (not shown in this view), similar to the clamp arm end <NUM> (<FIG>) configured to engage the nozzle segment <NUM> (opposite the first clamp assembly <NUM>) when tightened with the tightening assembly <NUM>.

<FIG> is a perspective view of an unclaimed device for sealing the turbine nozzle segment of <FIG> during manufacturing. A device <NUM> can receive the nozzle segment <NUM> between a first clamp assembly <NUM> and a second clamp assembly <NUM> on the support assembly <NUM>. The first clamp assembly <NUM> and the second clamp assembly <NUM> can be adjusted to secure the nozzle segment <NUM> and secure it during machining or milling.

The first clamp assembly <NUM> can have a securing assembly <NUM>. The first clamp assembly <NUM> can have a clamp arm <NUM>. The clamp arm <NUM> can slide toward and away from a central portion of the platform <NUM> (and the nozzle segment <NUM>) along the securing assembly <NUM>. The securing assembly <NUM> can be similar to the tightening assemblies <NUM>, <NUM>, having a threaded post or bolt and corresponding nut used to secure the clamp arm <NUM> in place between the clamp arm <NUM> and the support assembly <NUM>.

The clamp arm <NUM> can extend toward the center (or central portion) of the platform <NUM> (and toward the nozzle segment <NUM>, in use), having a first clamp arm end <NUM>. The first clamp arm end <NUM> can contact a portion of the nozzle segment <NUM> to retain the nozzle segment <NUM> securely in place within the device <NUM>.

The device <NUM> can also have one or more port seals <NUM> extending through a wall <NUM> in the clamp assembly <NUM>. As described in connection with <FIG>, the port seal <NUM> can seal the cooling cavity <NUM> of the nozzle segment <NUM>.

The second clamp assembly <NUM> can have a second securing assembly <NUM>. The second clamp assembly <NUM> can have a second clamp arm <NUM>. The second clamp arm <NUM> can slide toward and away from the nozzle segment <NUM> along the second securing assembly <NUM>. The second securing assembly <NUM> can be similar to the tightening assemblies <NUM>, <NUM>, having a threaded post or bolt and corresponding nut used to secure the clamp arm <NUM> in place.

The device <NUM> can further have a plunger <NUM>. The plunger <NUM> can have a thumb wheel <NUM> coupled to a post <NUM>. The post can be coupled to a plunger foot <NUM>. The post <NUM> can further be threaded within a plunger mount <NUM>. The plunger <NUM> can be used to further secure the nozzle segment <NUM> within the device <NUM> by rotation of the thumb wheel <NUM>. The thumb wheel <NUM> can be rotated to move the plunger foot <NUM> toward the center of the platform <NUM> and in a direction similar to the direction <NUM>.

<FIG> is a perspective view of the port seals of <FIG>. The port seals <NUM> can have a sealing member <NUM>. The sealing member <NUM> can be formed of a rubber or other polymer type substance. The sealing member <NUM> can be similar to the sealing members <NUM>, <NUM> and seal the cooling cavity <NUM> of the nozzle segment <NUM>, for example. The sealing member <NUM> can have a shape corresponding to that of the opening of the cooling cavity <NUM>. The sealing member <NUM> is shown having a foil-shaped profile, however this is not limiting on the disclosure. The sealing member <NUM> can have any shape, corresponding to that of the opening of the cooling cavity <NUM>.

The port seal <NUM> can have a seal platform <NUM>. The seal platform <NUM> can provide a rigid support for the sealing member <NUM>. The seal platform <NUM> can further provide a connection to seal legs <NUM>. The seal legs <NUM> are shown as seal legs 807a and 807b. The seal legs <NUM> can extend through the wall <NUM>, in use. The seal legs <NUM> can each have a leg axis <NUM> (shown as 805a, 805b). The seal legs <NUM> extend from the seal platform <NUM> substantially parallel to one another and orthogonal to the seal platform <NUM>. The seal legs <NUM> can further extend through coaxial springs <NUM> (<FIG>). The coaxial springs <NUM> can exert a force on the seal platform <NUM> pushing the port seal <NUM> in the direction of an arrow (direction) <NUM>.

<FIG> is a perspective view of the device of <FIG>, showing a cutaway of the port seal and nozzle segment. The device <NUM> can have one or more port seals <NUM> based on the number of cooling cavities <NUM> present in the nozzle segment <NUM>. The device <NUM> is shown, with a portion of the wall <NUM> removed, exposing the port seal 804b. The seal legs <NUM> of the port seal 804b extend through the wall <NUM> and coaxial springs <NUM>. The coaxial springs <NUM>, supported on one end by the wall <NUM>, impart a force on the seal platform <NUM> pushing the sealing member <NUM> toward the center of the support assembly <NUM>. When the nozzle segment <NUM> is present, the coaxial springs <NUM> provide a force pushing the port seals <NUM> toward the nozzle segment <NUM>, sealing the cooling cavities <NUM>. The coaxial springs <NUM> can be received on the seal legs <NUM> can rest (e.g., be compressed) between the seal platform <NUM> and the wall <NUM>. The port seals <NUM> can then move along the axes <NUM> in and out of the wall <NUM>, or toward and away from the center of the support assembly <NUM>.

The plunger <NUM>, the first clamp assembly <NUM>, and the second clamp assembly <NUM> can secure the nozzle segment <NUM> in place opposing the force exerted on the nozzle segment <NUM> by the springs <NUM>. The plunger <NUM> can be used to adjust the angle of the nozzle segment in the grooves <NUM> (<FIG>) or further secure it to the support assembly <NUM>, for example.

The device <NUM> and the port seals <NUM> can further have adjustment levers <NUM>. The adjustment levers <NUM> can be coupled to respective barrels <NUM> and axles <NUM>. The barrels <NUM> can have an eccentric external profile. Thus when moving the adjustment lever <NUM> about the axle <NUM>, the barrels <NUM> can push the port seals toward the secured nozzle segment <NUM>.

<FIG>is another unclaimed device for sealing the turbine nozzle segment of <FIG> during manufacturing. A device <NUM> can have a similar function as the devices <NUM>, <NUM>, <NUM>, securing the nozzle segment <NUM> and sealing the cooling cavities <NUM> to prevent contamination during milling or machining. The device <NUM> can have a first clamp assembly <NUM>. The first clamp assembly <NUM> can have a clamp arm <NUM>. The clamp arm <NUM> can be coupled to a hinge support <NUM> at a hinge assembly <NUM> having a pivot point <NUM>. The clamp arm <NUM> can pivot about the pivot point <NUM> in the x-z plane and about the y-axis (shown in <FIG>), substantially orthogonal to the support assembly <NUM>. The movement of the clamp arm <NUM> can provide sufficient clearance to place the nozzle segment <NUM> onto support assembly <NUM>.

The clamp arm <NUM> can be secured in place at a clamp arm distal end <NUM> by a tightening assembly <NUM>. Similar to other tightening assemblies disclosed herein, the tightening assembly <NUM> can have a threaded post or bolt and corresponding nut as needed to secure the clamp arm <NUM> (and the nozzle segment <NUM>) in place on the support assembly <NUM>. The device <NUM> can also have the plunger <NUM> (<FIG>). As described above, the plunger <NUM> can be used apply pressure to the nozzle segment <NUM> in the x- and y-axes and adjust the positioning of the nozzle segment <NUM> upon the support assembly <NUM>.

The device <NUM> can have a port seal assembly <NUM>. The port seal assembly <NUM> can have a port seal <NUM> and an actuation assembly <NUM>. The port seal <NUM> is described in more detail below. The actuation assembly <NUM> can have a lever <NUM> coupled to the port seal <NUM> via an actuation arm <NUM> and one or more hinge assemblies <NUM>. Three hinge assemblies <NUM> (946a, 946b, 946c) are shown in <FIG>, however this is not limiting on the disclosure. The actuation assembly <NUM> is configured to move the port seal <NUM> into a position to cover the cooling cavities <NUM>; accordingly, the hinge assemblies <NUM> can provide a lever action to perform the (horizontal, x-y plane) movement and secure the port seal <NUM> in place.

<FIG> is a top plan view of the device for sealing the turbine nozzle segment of <FIG>. The actuation assembly <NUM> of the device <NUM> can be moved in a horizontal plane (e.g., the x-y plane, as shown) to move the port seal <NUM> toward and away from the center of the support assembly <NUM>. This can also move the port seal <NUM> toward and away from the cooling cavity(ies) <NUM> of the nozzle segment <NUM> that is secured by the first clamp assembly <NUM> and the plunger <NUM>.

In use, the nozzle segment <NUM> can be placed up on the support assembly <NUM> of the device <NUM>, and the clamp arm <NUM> rotated about the pivot point <NUM> about the y-axis (e.g., in an out of the page). The tightening assembly <NUM> can be used to secure the nozzle segment <NUM> between the clamp arm <NUM> and the support assembly <NUM>. The plunger <NUM> can be tightened, using the thumb wheel <NUM> to move the plunger foot <NUM> (via the threaded post <NUM>) to contact the nozzle segment <NUM>.

Once secured on the support assembly <NUM>, the lever <NUM> can be moved in the direction of an arrow (direction) <NUM>. The cooperation of the hinge assemblies <NUM> move the port seal <NUM> toward the secured nozzle assembly in an arcuate path that lies substantially in the x-y plane.

<FIG> is a perspective view of the port seal of <FIG>. The port seal <NUM> can perform similar functions as the port seal <NUM>, <NUM>, <NUM>, sealing the cooling cavity(ies) <NUM>. The port seal <NUM> can have a port seal platform <NUM>. The port seal platform <NUM> can form the structure supporting the other components of the port seal <NUM>. The port seal <NUM> can have sealing members 932a, 932b (collectively sealing members <NUM>). The sealing members <NUM> can be similar to those described above and seal the cooling cavities <NUM>.

The port seal platform <NUM> can have a connection point <NUM>. The connection point <NUM> can be a threaded cavity, for example. The connection point <NUM> can couple the port seal <NUM> to the actuation arm <NUM> via hardware <NUM> (<FIG>) having corresponding external threads, for example. The hardware <NUM> can be a nut, bolt, washer, or other applicable hardware to attach the port seal <NUM> to the actuation arm <NUM> and the rest of the port seal assembly <NUM>. The connection point <NUM> can thus be, for example, a threaded channel (as shown) formed to receive a threaded post (e.g., the hardware <NUM>).

<FIG> is an elevation view of the port seal of <FIG>. The connection point <NUM> can fit within a flex hinge <NUM>. The flex hinge can allow motion in two of three axes. For example, the flex hinge <NUM> can a small amount of flexion about a longitudinal axis in a direction shown by the arrows (direction) <NUM> and in a direction described by an arrow (direction) <NUM>, but inhibit rotation about a vertical axis <NUM>. The ability to flex in two of three axes provide a more secure fit for the sealing members <NUM> within the cooling cavity(ies) <NUM>.

The port steal <NUM> can also have a guide post <NUM>. The guide post <NUM> can fit within a corresponding structure in the actuation arm <NUM> (not shown) to further restrict movement of the flex hinge <NUM> about the axis <NUM>.

During manufacturing, the nozzle segments <NUM> that form a gas turbine nozzle <NUM> can be cast from one or more metallic materials. The cast nozzle segments <NUM>, can have the cooling cavities <NUM> that allow air to flow and cool the nozzle <NUM> when in use within the gas turbine engine <NUM>. Cooling air can be directed into the cooling cavities <NUM> can out a plurality of cooling holes or apertures, such as leading edge cooling apertures <NUM>. The leading edge cooling apertures <NUM> can be pressure side cooling apertures and/or showerhead cooling apertures. The airfoil <NUM> can also have trailing edge cooling apertures <NUM>. Each cooling hole or cooling aperture <NUM>, <NUM> may be a channel extending through a wall of the airfoil <NUM>. Each set of cooling apertures <NUM> may be grouped together in a pattern, such as in a row or in a column. Such apertures are very fine and easily clogged with the introduction of particular matter into the cooling apertures.

During manufacturing, certain applications for the nozzle segments can require additional machining or milling prior to installation in the gas turbine engine <NUM>. Thus, the device for sealing the turbine nozzle segment <NUM>, <NUM>, <NUM>, <NUM> can be implemented to seal the openings of the cooling cavities <NUM> and prevent intrusion of any particles or other contaminants that may be created or introduced during milling of the nozzle segment <NUM>.

As described herein, the nozzle segment <NUM> requiring further milling, can be secured upon the support assembly <NUM> by one or more clamp assemblies. One or more port seals can then be engaged to the openings of the cooling cavity(ies) <NUM> to prevent contamination.

Claim 1:
A device (<NUM>, <NUM>, <NUM>, <NUM>) for securing a gas turbine nozzle segment (<NUM>) and sealing one or more cooling cavities of the gas turbine nozzle segment during manufacturing, the device comprising:
a support assembly (<NUM>) for receiving a nozzle segment having at least one cooling cavity (<NUM>);
a first clamp assembly configured to secure a first portion of the nozzle segment to the support assembly, the first clamp assembly (<NUM>) having a first clamp arm (<NUM>), and a first tightening assembly (<NUM>) coupling the first clamp arm to the support characterised in the device further comprising:
a first port seal assembly having
a first seal body (<NUM>) hingeably attached to the support assembly, and
at least one sealing member (<NUM>) coupled to the first seal body and configured to interact with and seal the corresponding one or more cooling cavities.