Patent ID: 8813359

Claim:
A process of manufacturing leaf seals for effecting seals between coaxial, relatively rotating components, each leaf seal having an annular pack of leaves which are stacked face-to-face within the pack, and which are mountable to one of the components at respective root portions of the leaves such that the leaves extend towards a sealing surface of the other component and respective edges of the leaves are presented for wiping contact with the sealing surface, the annular pack having a pack radius at the wiping contact edges which is matched within tolerance limits to the radius of the sealing surface to prevent, at one extreme, excessive interference of the leaves with the sealing surface and, at the other extreme, insufficient sealing; wherein the process includes the steps of: (a) determining production parameters for the production of a plurality of leaf seals for use with a seal surface having a given radius, the parameters being determined such that at least a portion of the produced leaf seals will have pack radii which violate the tolerance limit for preventing excessive interference; (b) producing the leaf seals using the determined production parameters; and (c) modifying the pack radii of the portion of the produced leaf seals which violate the tolerance limit for preventing excessive interference such that the modified pack radii match the sealing surface within the tolerance limits.