Methods for fabricating gas turbine engines

Abstract

Methods and apparatus of fabricating gas turbine engine components are provided. The method includes positioning a non-consumable shield adjacent to an edge of the component such that a gap is defined between the shield and the component, wherein the shield and gap form a fluid flow restriction adjacent to the edge, and inducing an electrical current from an anode to the component through an electrolyte bath such that a coating is applied to the component.

Description

CROSS REFERENCE TO RELATED APPLICATIONS[0001]This application is a divisional and claims priority to U.S. Patent Application Ser. No. 10 / 921,502 filed Aug. 19, 2004 for “METHODS FOR FABRICATING GAS TURBINE ENGINES”, which is hereby incorporated by reference in its entirety.BACKGROUND OF THE INVENTION[0002]This invention relates generally to turbine engines, and more specifically to environmental coatings used with turbine engine components.[0003]At least some known gas turbine engines include a forward fan, a core engine, and a power turbine. The core engine includes at least one compressor that provides pressurized air to a combustor wherein the air is mixed with fuel and ignited for generating hot combustion gases. The combustion gases flow downstream to one or more turbines that extract energy therefrom to power the compressor and provide useful work, such as powering an aircraft. A turbine section may include a stationary turbine nozzle positioned at the outlet of the combustor ...

AI Technical Summary

Benefits of technology

This method achieves a 40% improvement in uniformity of metallic film coating thickness around the perimeter of the vane, reducing the need for frequent replacements and enhancing the durability of the coating.

Problems solved by technology

However, an electric field generated by current flow between the component to be coated and an anode used in coating may be non-uniformly distributed across the component, and more specifically such flux lines may be more dense adjacent sharp edges on the part, such as adjacent the trailing edge of the nozzle vane.

Over time, the uneven distribution of coatings may cause cracking: At least one known method of controlling the electroplate thickness adjacent the trailing edge requires that a disposable, metallic “robber” be positioned adjacent to the trailing edge to thieve current from the edge during the coating application.

However, within such methods the effectiveness of the robber degrades over time and it may require frequent replacement.

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