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A method of forming an interstage seal including removing a diaphragm seal box (14) from a gas turbine compressor assembly (10) and removing a labyrinth sealing member (12) from the diaphragm seal box (14). An abradable material layer (34) may be deposited on the diaphragm seal box (14). A spray gun

A method of forming an interstage seal including removing a diaphragm seal box (14) from a gas turbine compressor assembly (10) and removing a labyrinth sealing member (12) from the diaphragm seal box (14). An abradable material layer (34) may be deposited on the diaphragm seal box (14). A spray gun may be mounted in relation to an engine disk (16) of the gas turbine compressor assembly (10) for cold-spraying a quantity of particles toward the engine disk (16). The particles may be sprayed at a velocity sufficiently high to cause at least a portion of the quantity of particles to adhere to the engine disk (16). The spray gun may be controlled to deposit a quantity of particles on the compressor disk (16) to form a geometry (32) that will abrade the abradable material layer (34) during operation of the gas turbine compressor assembly (10). The geometry (32) abrading the abradable material layer (34) forms an interstage seal. Rotation of the engine disk (16) within the gas turbine compressor assembly (10) may be controlled during the step of controlling the spray gun. The diaphragm seal box (14) may be reinstalled within the gas turbine compressor assembly (10) so that the geometry (32) aligns with the abradable material layer (34).

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We claim as our invention: 1. A method comprising: depositing an abradable material layer on a diaphragm seal box of a gas turbine compressor assembly; cold-spraying a quantity of particles toward an engine disk of the gas turbine compressor assembly at a velocity sufficiently high to cause at leas

We claim as our invention: 1. A method comprising: depositing an abradable material layer on a diaphragm seal box of a gas turbine compressor assembly; cold-spraying a quantity of particles toward an engine disk of the gas turbine compressor assembly at a velocity sufficiently high to cause at least a portion of the quantity of particles to adhere to the engine disk to form a geometry that will abrade the abradable material layer during operation of the gas turbine compressor assembly to form an interstage seal; and forming the geometry with a number of layers selected to cause the geometry to be fully dense near its centerline due to a peening action of subsequent ones of the layers. 2. The method of claim 1 further comprising: the step of removing the diaphragm seal box from the gas turbine compressor assembly is performed prior to the step of depositing; and removing a plurality of labyrinth sealing members from the diaphragm seal box prior to the step of depositing. 3. The method of claim 1 further comprising: the step of removing the diaphragm seal box from the gas turbine compressor assembly is performed prior to the step of depositing; depositing the abradable material layer on an inside circumference of the diaphragm seal box; and controlling the rotation of the engine disk during the cold-spraying to form the geometry comprising a substantially triangular cross section. 4. The method of claim 1 further comprising: controlling the rotation of the engine disk during the cold-spraying to form the geometry comprising a substantially triangular cross section. 5. The method of claim 4, the geometry comprising a height-to-width ratio of approximately 2-to-1. 6. The method of claim 4, the geometry comprising a height of about 6 to 7 millimeters and a width of about 2 to 3 millimeters. 7. The method of claim 1 further comprising: controlling the rotation of the engine disk during the cold-spraying to form the geometry comprising at least two parallel ridges around an outer circumference of the engine disk, each of the at least two parallel ridges comprising a substantially triangular cross section. 8. The method of claim 7, each of the at least two parallel ridges comprising a height-to-width ratio of approximately 2-to-1. 9. The method of claim 7, each of the at least two parallel ridges comprising a height of about 6 to 7 millimeters and a width of about 2 to 3 millimeters. 10. The method of claim 1 further comprising: removing the diaphragm seal box from the gas turbine compressor assembly prior to the step of depositing; mounting a spray gun in fixed relation to the engine disk for cold-spraying the quantity of particles toward the engine disk; and controlling rotation of the engine disk mounted within the gas turbine compressor assembly during the step of cold-spraying. 11. The method of claim 10 further comprising: the rotation of the engine disk during controlling the cold-spraying to form the geometry comprising a substantially triangular cross section, at least one ridge formed around an outer circumference of the engine disk. 12. A method comprising: removing a diaphragm seal box from a gas turbine compressor assembly; removing a labyrinth sealing member from the diaphragm seal box; depositing an abradable material layer on the diaphragm seal box after removing the diaphragm seal box from the gas turbine compressor assembly; mounting a spray gun in relation to an engine disk of the gas turbine compressor assembly, the spray gun configured for cold-spraying a quantity of particles toward the engine disk at a velocity sufficiently high to cause at least a portion of the quantity of particles to adhere to the engine disk; controlling the spray gun to deposit the quantity of particles on the engine disk to form a geometry that will abrade the abradable material layer during operation of the gas turbine compressor assembly to form an interstage seal; controlling rotation of the engine disk within the gas turbine compressor assembly during the step of controlling the spray gun so that the geometry is formed by a plurality of layers of spray-deposited material and is fully dense near its centerline due to a peening action of subsequent ones of the layers; and reinstalling the diaphragm seal box within the gas turbine compressor assembly so that the geometry aligns with the abradable material layer. 13. The method of claim 12 further comprising: forming the geometry comprising a substantially triangular cross section. 14. The method of claim 13 further comprising: forming the geometry having an aspect ratio of approximately 2 to 1. 15. The method of claim 12 further comprising: controlling the spray gun to form at least two parallel ridges on the engine disk each of the at least two parallel ridges having a substantially triangular cross section. 16. The method of claim 12 further comprising: controlling the spray gun to form at least two parallel ridges on the engine disk each of the at least two parallel ridges having a height of about 6 to 7 millimeters and a width of about 2 to 3 millimeters. 17. A method comprising: depositing a layer of abradable material on a diaphragm seal box of a gas turbine compressor assembly; and forming a ridge around an outer circumference surface of an engine disk of the gas turbine compressor assembly by cold-spraying particles onto the surface in a plurality of layers, a width of each respective layer being smaller than a preceding layer such that the ridge takes a knife-edge shape, a number of the plurality of layers selected to cause the ridge to be fully dense near its centerline due to a peening action of subsequent layers; the abradable material and ridge cooperating to form a seal when the gas turbine is operated.