Electrospark deposition process for oxidation resistant coating of cooling hole

Abstract

A method of providing an oxidation resistant coating is disclosed. The method includes providing a substrate having a first surface and cooling holes. A portable coating device includes electro-spark deposition (ESD) equipment and an ESD torch connected with the ESD equipment. The ESD torch has an inert gas source and a rotary electrode conductive material. The rotary electrode is positioned within the ESD torch, and is shielded by an inert gas. The rotary electrode applies a compositionally controlled protective coating to the first surface of the substrate. Then the rotary electrode is inserted into the cooling hole and generates an electrospark between rotary ESD electrode and the substrate to form a rounded edge and deposit a coating of electrode material alloy at a cooling hole edge.

Description

FIELD OF THE INVENTION[0001]This application generally relates to gas turbine components. The application relates more specifically to the use of an electrospark deposition process to apply an oxidation resistant coating to a cooling hole of a gas turbine component.BACKGROUND OF THE INVENTION[0002]Many component parts of a gas turbine engine include cooling holes for active cooling of engine sections located downstream of the turbine section. The rising combustor exit temperatures in gas turbine engines necessitate active cooling to avoid thermal failure. For example, a transition piece for a gas turbine engine typically includes an integral frame portion surrounding an opening at a downstream end where the transition piece connects to the turbine stage. An exemplary transition piece is described in U.S. Pat. No. 5,414,999.[0003]Under the high temperature operating conditions of the gas turbine engine, fracture or cracks may occur around the cooling holes located on portions of the ...

AI Technical Summary

Benefits of technology

The present patent describes a method to improve the resistance of a cooling hole exit to oxidation by applying an ESD process with a specific tip profile. This process forms a rounded edge with an alloy coating that prevents the substrate metal from oxidizing. The method reduces the number of turbine components that are scrapped or discarded and also builds up a superior resistance to oxidation of the metal substrate.

Problems solved by technology

Under the high temperature operating conditions of the gas turbine engine, fracture or cracks may occur around the cooling holes located on portions of the frame.

Failure analysis has revealed that such cracks form perpendicular to the inner surface of the frame, which indicates that thermal stresses played a role in forming the cracks occurring at the cooling hole.

Grain boundary oxidation and thermal fatigue are potential causes of such cracking.

Analysis indicated that cracks in the cooling holes of the frame followed the oxidized grain boundaries.

Currently there is no process to prevent crack initiation at the aft end of the cooling holes.

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