Seal systems for use in turbomachines and methods of fabricating the same

1. A seal system for an apparatus that includes a rotatable portion and a stationary portion extending over at least a portion of the rotatable portion, the stationary portion includes an inner surface, the rotatable portion includes at least one airfoil assembly coupled thereto, wherein the at least one airfoil assembly includes a substrate, said seal system comprising:

an abradable portion comprising at least one abradable layer of an abradable material formed over at least a portion of the inner surface, wherein said abradable portion comprises an abradable surface face; and

an abrading portion disposed over at least a portion of the substrate, said abrading portion comprising:

at least one abrading layer formed on at least a portion of said substrate, wherein said at least one abrading layer defines an abrading layer surface; and

a plurality of abrasive particles embedded within said at least one abrading layer, wherein at least a portion of said plurality of abrasive particles extends beyond said abrading layer surface a first predetermined distance within a range between approximately 0% and 40% of an equivalent diameter of said plurality of abrasive particles, said plurality of abrasive particles are separated from each other with a spacing range between approximately 20μ and approximately 500μ, and said plurality of abrasive particles comprises at least one of:

substantially all of one of tantalum carbide (TaC), aluminum oxide (Al 2 O 3 ), and ziconia (ZrO 2 );

cubic boron nitride (cBN) and Al 2 O 3 in predetermined ratios;

cBN, Al 2 O 3 , and ZrO 2 in predetermined ratios;

Al 2 O 3 and ZrO 2 fused together in predetermined ratios; and

TaC and Al 2 O 3 in predetermined ratios,

wherein the abrading portion rubs against the abradable portion and defines a clearance gap between the abrading portion and the abradable portion, further defines a second predetermined distance between said abrading layer surface and said abradable surface face, and further wherein the clearance gap comprises a predetermined range of values, and further wherein said first predetermined distance and said second predetermined distance reduce a potential of contact between said abrading layer and said abradable shroud.

2. The seal system in accordance with claim 1 , wherein said plurality of abrasive particles further comprises:

particles sized in a range between approximately 50.8 microns (μ) and approximately 500μ.

3. The seal system in accordance with claim 1 , wherein said at least one abrading layer comprises at least one of at least one metallic layer and at least one ceramic layer.

4. The seal system in accordance with claim 1 , wherein said at least one abrading layer has a first hardness value and said plurality of abrasive particles has a second hardness value, wherein the second hardness value is greater than the first hardness value.

5. The seal system in accordance with claim 1 , wherein said plurality of abrasive particles further comprises at least some silicon carbide (SiC) particles comprising an external inert particle coating comprising at least one of Al 2 O 3 and mullite.

6. The seal system in accordance with claim 1 , wherein said at least one abrading layer comprises at least one of yttria-stabilized zirconia (YSZ), zirconia-toughened alumina, alumina-toughened zirconia, Al 2 O 3 , and hafnia (HfO 2 ).

7. The seal system in accordance with claim 1 , wherein said at least one abrading layer comprises at least one of:

a chromium-aluminum-yttrium alloy (MCrAlY), wherein M comprises at least one of nickel (Ni), cobalt (Co), and iron (Fe) in any combination thereof;

a chromium-aluminum alloy (MCrAlX), wherein M comprises at least one of nickel (Ni), cobalt (Co), and iron (Fe) in any combination thereof, and X comprises at least one of hafnium (Hf), Y, Si, and Ta in any combination thereof; and

an alloy comprising at least two of nickel (Ni), aluminum (Al), and platinum (Pt) in any combination thereof.

8. The seal system in accordance with claim 1 , wherein said at least abrading one layer has a thickness within a range between approximately 50.8μ, and approximately 500μ.

9. The seal system in accordance with claim 1 , wherein said abradable portion comprises at least one of:

dense vertically-cracked (DVC) yttria-stabilized zirconia (YSZ); and

dense vertically-cracked (DVC) dysprosia-stabilized zirconia (DySZ).

10. The seal system in accordance with claim 9 , wherein said DVC YSZ has a porosity value of less than 5%.

11. The seal system in accordance with claim 9 , wherein said DVC DySZ has a porosity value of less than 5%.

12. The seal system in accordance with claim 9 , wherein said abradable portion is formed with a thickness of at least approximately 500μ.

13. The seal system in accordance with claim 1 , wherein said clearance gap reduces a flow of a working fluid between said stationary portion and said rotatable portion.

14. A method of assembling a seal system for an apparatus, said method comprising:

providing a rotatable portion, wherein the rotatable portion includes at least one airfoil assembly coupled thereto, the at least one airfoil assembly includes a substrate;

extending a stationary portion over the at least a portion of the rotatable portion, wherein the stationary portion includes an inner surface;

forming an abradable portion comprising at least one layer of abradable material on at least a portion of the inner surface and further comprising an abradable surface face; and

forming an abrading portion comprising at least one matrix layer comprising an abrading layer surface, on at least a portion of the substrate, wherein the at least one matrix layer includes a plurality of abrasive particles embedded within the at least one matrix layer, wherein at least a portion of said plurality of abrasive particles extends beyond said abrading layer surface a first predetermined distance within a range between approximately 0% and 40% of an equivalent diameter of said plurality of abrasive particles, wherein the plurality of abrasive particles are separated from each other with a spacing range between approximately 20μ and approximately 500μ, wherein the plurality of abrasive particles includes at least one of:

substantially all of one of tantalum carbide (TaC), aluminum oxide (Al 2 O 3 ), and ziconia (ZrO 2 );

cubic boron nitride (cBN) and Al 2 O 3 in predetermined ratios;

cBN, Al 2 O 3 , and ZrO 2 in predetermined ratios;

Al 2 O 3 and ZrO 2 fused together in predetermined ratios; and

TaC and Al 2 O 3 in predetermined ratios,

wherein the abrading portion rubs against the abradable portion and defines a clearance gap between the abrading portion and the abradable portion, further defines a second predetermined distance between said abrading layer surface and said abradable surface face, and further wherein the clearance gap comprises a predetermined range of values, and further wherein said first predetermined distance and said second predetermined distance reduce a potential of contact between said abrading layer and said abradable shroud.

15. The method in accordance with claim 14 , wherein forming at least one layer of abradable material on the inner surface comprises spraying at least one of dense vertically-cracked (DVC) yttria-stabilized zirconia (YSZ) and dense vertically-cracked (DVC) dysprosia-stabilized zirconia (DySZ) on the inner surface, wherein the at least one layer of abradable material has a first hardness value, and the plurality of abrasive particles has a second hardness value, the second hardness value is greater than the first hardness value.

16. The method in accordance with claim 14 , wherein forming at least one matrix layer comprises forming a braze matrix comprising mixing at least one of silicon (Si), titanium (Ti), tungsten (W), boron (B) and zirconium (Zr) with at least one of nickel chrome (NiCr) and Ni.

17. The method in accordance with claim 14 , wherein forming at least one matrix layer comprises:

forming a chromium-aluminum-yttrium alloy (MCrAlY) matrix, wherein M comprises at least one of nickel (Ni), cobalt (Co), and iron (Fe) in any combination thereof; and

forming at least one MCrAlY matrix layer through an electrolytic process.

18. The method in accordance with claim 14 , wherein forming at least one matrix layer comprises:

forming a brazing compound comprising mixing at least one of silicon (Si), titanium (Ti), tungsten (W), boron (B) and zirconium (Zr) with at least one of nickel chrome (NiCr) and Ni;

applying the brazing compound to the at least a portion of the substrate;

brazing the plurality of particles to the substrate;

forming an electrolytic compound comprising forming a MCrAlY matrix compound, wherein M comprises at least one of nickel (Ni), cobalt (Co), and iron (Fe) in any combination thereof; and

applying the electrolytic compound to the brazed particles and filling in at least a portion of the spacing therebetween.

19. The method in accordance with claim 14 , wherein said clearance gap reduces a flow of a working fluid between said stationary portion and said rotatable portion.

20. A method of operating an apparatus that includes a rotatable portion and a stationary portion extending over at least a portion of the rotatable portion, the stationary portion includes an inner surface, the rotatable portion includes at least one airfoil assembly coupled thereto, said method comprising:

inducing a rotation in the rotatable member such that an abrading portion of a seal system rubs against an abradable portion of the seal system, wherein the abradable portion comprises an abradable surface face and includes at least one layer of at least one of dense vertically-cracked (DVC) yttria-stabilized zirconia (YSZ) and dense vertically-cracked (DVC) dysprosia-stabilized zirconia (DySZ) formed on the stationary portion, the abradable portion having a first hardness value, and the abrading portion includes a plurality of abrasive particles embedded within at least one matrix layer, wherein said at least one matrix layer defines an abrading layer surface, and further wherein at least a portion of said plurality of abrasive particles extends beyond said abrading layer surface a first predetermined distance within a range between approximately 0% and 40% of an equivalent diameter of said plurality of abrasive particles, wherein the plurality of abrasive particles are separated from each other with a spacing range between approximately 20μ and approximately 500μ, wherein the plurality of abrasive particles has a second hardness value that is greater than the first hardness value, and the plurality of abrasive particles includes at least one of:

substantially all of one of tantalum carbide (TaC), aluminum oxide (Al 2 O 3 ), and ziconia (ZrO 2 );

cubic boron nitride (cBN) and Al 2 O 3 in predetermined ratios;

cBN, Al 2 O 3 , and ZrO 2 in predetermined ratios;

Al 2 O 3 and ZrO 2 fused together in predetermined ratios; and

TaC and Al 2 O 3 in predetermined ratios; and

removing at least a portion of the abradable portion with the abrading portion; and

defining a clearance gap between the abradable portion and the abrading portion, wherein the clearance gap comprises a predetermined range of values, and further defining a second predetermined distance between said abrading layer surface and said abradable surface face wherein said first predetermined distance and said second predetermined distance reduce a potential of contact between said matrix layer and said abradable shroud.

21. The method in accordance with claim 20 , wherein the abradable portion is formed with at least one of a substantially smoothed surface and a patterned surface.

22. The method in accordance with claim 20 , wherein said clearance gap reduces a flow of a working fluid between said stationary portion and said rotatable portion.