FIELD

The present disclosure relates to face seals arrangements, more specifically, to improving wear performance of dry face carbon seals.

BACKGROUND

Carbon face seals may typically be arranged about gas turbine engine shafts and tend to protect gas turbine engine hardware from hot gases in the turbine engine gas path. A portion of newly installed carbon face seals tend to exhibit premature sealing face wear during start up attributable to increased friction loading at the sealing face during the startup condition. In this regard, the carbon face seal may tend to have decreased sealing performance and may tend to result in damage to the gas turbine engine or gas turbine engine hardware surrounding the seal.

SUMMARY

In various embodiments, an improved face seal is provided comprising a seal housing comprising an annular extrusion, and a primary seal coupled to the seal housing, wherein the primary seal comprises a sealing face and a base opposite the sealing face, wherein the primary seal has an annular structure coaxial with the annular extrusion with the base proximate a first end of the seal housing, wherein the sealing face comprises a disrupted surface.

In various embodiments, the improved face seal further comprises a seal support, wherein the annular extrusion is disposed within the seal support, wherein the annular extrusion comprises a secondary seal at a distal end of the annular extrusion opposite the primary seal. In various embodiments, the disrupted surface comprises a patterned portion. In various embodiments, the patterned portion comprises one of a circumferentially patterned portion, a hatch pattern portion, or a cross-hatch pattern portion. In various embodiments, the patterned portion comprises a plurality of ablated portions having a depth below the sealing face between 0.381 μm to 12.7 μm. In various embodiments, the patterned portion comprises a plurality of ablated portions having a spacing between each of a relatively adjacent ablated portion of the ablated portions between 0.08 mm and 0.25 mm. In various embodiments, the patterned portion comprises a plurality of ablated portions having an Ra between 0.381 μm to 2.667 μm. In various embodiments, the patterned portion comprises a plurality of ablated portions having an Rz between 2.413 μm to 11.43 μm.

In various embodiments, a gas turbine engine is provided comprising a compressor section configured to compress a gas, a combustor section aft of the compressor section configured to combust the gas, a turbine section aft of the combustor section configured to extract work from the gas, and an improved face seal, comprising a seal housing comprising an annular extrusion, and a primary seal coupled to the seal housing, wherein the primary seal comprises a sealing face and a base opposite the sealing face, wherein the primary seal has an annular structure coaxial with the annular extrusion with the base proximate a first end of the seal housing, wherein the sealing face comprises a disrupted surface.

In various embodiments, the improved face seal further comprises a seal support, wherein the annular extrusion is disposed within the seal support, wherein the annular extrusion comprises a secondary seal at a distal end of the annular extrusion opposite the primary seal. In various embodiments, the disrupted surface comprises a patterned portion. In various embodiments, the patterned portion comprises one of a circumferentially patterned portion, a hatch pattern portion, or a cross-hatch pattern portion. In various embodiments, the patterned portion comprises a plurality of ablated portions having a depth below the sealing face between 0.381 μm to 12.7 μm. In various embodiments, the patterned portion comprises a plurality of ablated portions having a spacing between each of a relatively adjacent ablated portion of the ablated portions between 0.08 mm and 0.25 mm. In various embodiments, the patterned portion comprises a plurality of ablated portions having an Ra between 0.381 μm to 2.667 μm. In various embodiments, the patterned portion comprises a plurality of ablated portions having an Rz between 2.413 μm to 11.43 μm.

In various embodiments an article of manufacture is provided. The article of manufacture includes a carbon face seal having a disrupted surface thereon, the disrupted surface comprising a patterned portion defined by a plurality of ablated portions on a sealing face of the carbon face seal wherein the ablated portions have a depth below the sealing face between 0.381 μm to 12.7 μm.

In various embodiments, the plurality of ablated portions have a spacing between each of a relatively adjacent ablated portion of the ablated portions between 0.08 mm and 0.25 mm. In various embodiments, the plurality of ablated portions have an Ra between 0.381 μm to 2.667 μm. In various embodiments, the plurality of ablated portions have an Rz between 2.413 μm to 11.43 μm.

The foregoing features and elements may be combined in various combinations without exclusivity, unless expressly indicated otherwise. These features and elements as well as the operation thereof will become more apparent in light of the following description and the accompanying drawings. It should be understood, however, the following description and drawings are intended to be exemplary in nature and non-limiting.

