Method and tool for fixing a component and method for coating an aerospace

Abstract

Methods and tools for securing components for a treatment process and methods for coating aerospace components using an electrically driven aqueous process are provided. A method for securing a component for a treatment process includes obtaining a tool for holding the component during the treatment process. The tool includes a cantilevered slab. The method includes associating the tool with the support bar and securing the component to the tool such that the cantilevered slab is in contact with the component.

Description

Technical Field

[0001] The present disclosure relates generally to the field of tools for securing parts for coating. More specifically, the present disclosure relates to tools that can be used for additive manufacturing of coated parts via an electrically driven waterborne process. Background Art

[0002] A simplified overview of the present invention is presented below to provide a basic understanding of some aspects of the present invention. This overview is not a broad overview of the present invention. It is not intended to identify key elements of the present invention or to describe the scope of the present invention. Its only purpose is to present some concepts of the present invention in a simplified form as a preface to the more detailed description presented elsewhere herein. Summary of the invention

[0003] In one aspect, a method for securing a component for a processing process includes obtaining a tool for holding the component during the processing process. The tool includes a cantilever plate. The method includes associating the tool with a support rod and securing the component to the tool such that the cantilever plate contacts the component.

[0004] In some aspects, according to any of the preceding aspects, a tool comprises a bracket and an adapter connectable by a shaft.

[0005] In some aspects, according to any of the preceding aspects, the cantilever plate extends from the rear surface of the adapter, and the shaft and adapter are additively manufactured as a unitary structure.

[0006] In some aspects, according to any of the preceding aspects, the bracket includes a socket having a channel.

[0007] In some aspects, according to any of the preceding aspects, the socket is accessible through an opening in the support rod.

[0008] In some aspects, according to any of the preceding aspects, the channel comprises an asymmetric shape and is configured to receive the shaft in only one orientation.

[0009] In some aspects, according to any of the preceding aspects, the method includes obtaining a cover configured to slide over the tool.

[0010] In some aspects, according to any of the preceding aspects, the method includes rotating the rotatable member to cause the cantilever plate to contact the component.

[0011] In some aspects, according to any of the preceding aspects, the method includes lowering a support rod and a part secured to a tool in an aqueous solution to coat the part using an electrically driven aqueous process.

[0012] In some aspects, according to any of the preceding aspects, the method includes associating a second tool with the support rod, and the tool and the second tool extend from the support rod at the same angle.

[0013] In some aspects, according to any of the preceding aspects, the tool includes an adapter configured to retain a dovetail of a blade of the gas turbine.

[0014] In some aspects, according to any of the preceding aspects, the adapter comprises two opposing cylindrical bars, and each opposing cylindrical bar is configured to interface with a dovetail joint.

[0015] In some aspects, a tool for securing a component for a process is disclosed. The tool includes a bracket and an adapter, the bracket including a socket having a channel, the adapter including a body, and the body including a cantilever plate. The adapter is configured to receive the component for the process. The tool includes a shaft configured to be received in the channel for coupling the adapter to the bracket.

[0016] In some aspects, according to any of the preceding aspects, the adapter includes a bolt passing through the body and coupled to the cantilever plate.

[0017] In some aspects, according to any of the preceding aspects, the channel comprises an asymmetric shape, and the shape of the shaft corresponds to the shape of the channel.

[0018] In some aspects, according to any of the preceding aspects, the processing process is an electrically driven aqueous process, the bracket is coupled to the support rod, and the adapter is manufactured using an additive process such that the body and the cantilever plate have a unitary structure.

[0019] In some aspects, according to any of the preceding aspects, the tool includes a polymer cover configured to slide over the adapter.

[0020] In some aspects, a method for coating an aerospace component using an electrically driven aqueous process is disclosed. The method includes obtaining an additively manufactured tool for holding an aerospace component during an electrically driven aqueous process. The tool includes: an adapter having a cantilever plate; a bracket having a socket having a channel; and a shaft coupled to the adapter and receivable within the socket to couple the adapter to the bracket. The method includes: securing the aerospace component to the adapter so that the cantilever plate contacts the aerospace component; coupling the adapter to the bracket via the shaft; and associating the bracket with a cathode rod.

[0021] In some aspects, according to any of the preceding aspects, the aerospace component includes a dovetail, the dovetail includes an end wall, and the cantilever plate contacts the end wall of the dovetail of the aerospace component.

[0022] In some aspects, according to any of the preceding aspects, the adapter includes two opposing cylindrical rods to engage a dovetail joint during an electrically driven aqueous process.

[0023] These and other features, aspects and advantages of the present invention will become better understood with reference to the following description and appended claims.The accompanying drawings, which are incorporated in and constitute a part of this specification, illustrate various aspects of the present invention and, together with the description, serve to explain the principles of the present invention. BRIEF DESCRIPTION OF THE DRAWINGS

[0024] Illustrative embodiments of the present disclosure are described in detail below with reference to the accompanying drawings.

[0025] Figure 1 is a perspective view of a gas turbine blade according to the prior art.

[0026] Figure 2A is a perspective view of a prior art cathode for coating blades using an electrically driven aqueous process.

[0027] Figure 2B yes Figure 2A Front view of a prior art cathode adapter.

[0028] Figure 2C yes Figure 2B A front view of a prior art adapter with a gas turbine blade secured to the prior art adapter.

[0029] Figure 3A is a perspective view of prior art cathodes with adapters that are misaligned with each other.

[0030] Figure 3B yes Figure 3A Front view of a deformed adapter of a prior art cathode.

[0031] Figure 4 is a perspective view of a cathode according to an embodiment of the present disclosure.

[0032] Figure 5 A method for coating a component in an electrically driven aqueous process according to an embodiment of the present disclosure Figure 4 A stereoscopic view of the cathode tool.

[0033] Fig. 6A and Figure 6B yes Figure 5 A perspective view of a tool holder.

[0034] Fig. 7A yes Figure 5 A perspective view of an adapter for a tool.

[0035] Figure 7B yes Fig. 7A Front view of the adapter.

[0036] Fig. 8A and Figure 8B is used for Fig. 7A A perspective view of a cover of an adapter.

[0037] Fig. 9 is Fig. 8A The cover is already connected to Fig. 7A After the adapter Fig. 7A A perspective view of the adapter.

[0038] Fig.10 In gas turbine blades and Fig. 8A The cover is fixed to Fig. 7A After the adapter Fig. 7A Front view of the adapter.

[0039] Fig.11A It shows Fig. 7A Schematic diagram of the cantilever plate of the adapter, Fig. 7A The cantilever plate of the adapter is spaced apart from the dovetail of the blade secured to the adapter.

[0040] Fig. 11B It shows Fig. 7A Schematic diagram of the cantilever plate of the adapter, Fig. 7A The cantilever plate of the adapter contacts the dovetail of the blade.

[0041] Fig. 12A is a perspective view of a support rod of a cathode according to an embodiment of the present disclosure.

[0042] Fig. 12B According to the embodiment of the present disclosure Fig. 12A A three-dimensional diagram of a support rod, wherein Fig. 12A Openings are introduced in the support rods.

[0043] Fig. 12C According to the embodiment of the present disclosure Fig. 12B A three-dimensional diagram of a support rod, wherein Fig. 12B The support rod has a bracket, and the socket of the bracket is arranged in the opening of the support rod.

[0044] Fig.12D According to the embodiment Fig. 12C A perspective view of a support rod with the shaft and adapter shown coupled to the socket to form a cathode.

[0045] Fig.12E According to the embodiment of the present disclosure Fig.12D A perspective view of the cathode showing the blades coupled to each adapter.

[0046] Fig.12F According to the embodiment Fig.12E A perspective view of a cathode in which the cover is arranged on the adapter and the blades.

[0047] Fig.13 is a flow chart illustrating a tool for additive manufacturing of cathodes and a method of using these tools for cathodes to coat parts in an electrically driven aqueous process according to an embodiment of the present disclosure.

[0048] Fig.14 is a front view of another prior art adapter for coating blades in an electrically driven aqueous process.

[0049] Fig.15 It is a bottom stereogram of a blade in the prior art.

[0050] Fig.16 is a perspective view of another tool for coating parts with an electrically driven aqueous process according to an embodiment of the present disclosure.

[0051] Fig.17 yes Fig.16 Another stereoscopic view of the tool. DETAILED DESCRIPTION

[0052] The term electrophoretic deposition (EPD) is used for a wide range of industrial processes, including electrocoating, cathode electrodeposition, anodic electrodeposition, electrophoretic coating and electrophoretic painting. The feature of EPD is that colloidal particles suspended in a liquid medium migrate and are deposited on electrodes under the influence of an electric field (electrophoresis). All colloidal particles that can be used to form a stable suspension and can carry an electric charge can be used for electrophoretic deposition. This includes materials such as polymers, pigments, dyes, ceramics and metals. Water-based EPD and other electrically driven water-based processes are typically used to apply coatings to metal manufacturing products, such as automotive bodies and parts, tractors and heavy equipment, electrical switchgear, appliances, metal furniture, beverage containers, fasteners and many other industrial products.

[0053] Electric driven waterborne processes are also used in the aerospace industry to coat various parts. Electric driven waterborne processes can be used to coat aerospace parts to achieve desired electrical and corrosion resistance, reduce wear and friction, improve heat resistance, etc. Gas turbine blades and vanes are examples of aerospace parts that can be coated using one or more electric driven waterborne processes.

[0054] Figure 1A gas turbine blade 10 is shown as known in the art. The turbine blade 10 generally includes an airfoil 12 extending from a top or gas path side surface 14 of a platform 16 and a root fixing portion or "dovetail" 18 depending from a lower surface 20 of the platform 16. The dovetail 18 may include one or more serrations or tongues 22 extending laterally from one side 23A of the dovetail 18 to an opposite side 23B of the dovetail 18. The dovetail 18 may terminate at an end or bottom wall 25 that may span between the dovetail sides 23A, 23B. The dovetail 18 (including the tongue 22 and its bottom wall 25) may be adapted for interlocking engagement in a corresponding groove defined in an outer edge of a hub of a turbine rotor.

[0055] The airfoil 12 may have a pressure side 26, a suction side opposite the pressure side 26, and a tip 28. The tip 28 may be configured to interact with a tip shroud, for example, to reduce leakage of hot combustion gases over the tip 28. The airfoil 12 (e.g., its pressure side) may be in contact with combustion gases at extremely high temperatures. The airfoil 12 or portions thereof may therefore be coated with a heat resistant coating. During operation, the tip 28 may rub against the tip shroud, so the tip 28 may be additionally or alternatively coated with a wear resistant coating. In a similar manner, one or more other portions of the blade 10 may be coated with different materials, depending on the environment in which these portions are located and the stresses encountered thereby.

[0056] One or more portions of the blade 10 may be coated using an electrically driven waterborne process. The electrically driven waterborne coating process may employ a cathode and an anode. Figure 2A An example cathode 30 is shown as is known in the art. A component, such as an aerospace component (eg, blade 10) or other component, may be secured to cathode 30 to enable coating via an electrically driven aqueous process.

[0057] The cathode 30 may have a support rod 32 extending laterally. A plurality of connecting members 34 may be fixed to the support rod 32 and suspended from the support rod 32. Each connecting member 34 may have an adapter 36 fixed thereto. Therefore, each connecting member 34 may connect an adapter 36 to the support rod 32 so that the connecting member 34 extends between the adapter 36 and the support rod 32. The parts to be coated (such as blades or vanes, etc.) may be fixed to an adapter 36, respectively. The cathode 30 may be lowered into the aqueous solution together with the parts fixed to its adapter 36. The anode (such as a conformal mesh or another anode, etc.) may be located at a given distance in the aqueous solution. The interaction between the cathode and the anode may generate energy transfer, thereby causing each part fixed to the adapter 36 to be coated. For example, the parts may be coated with platinum (such as platinum aluminide, etc.), cubic raw nitride (CBN) or another coating. In application, a part of the part may be covered to allow another part of the multiple parts of the part to be coated in the aqueous solution.

[0058] Figure 2B An adapter 36 of the cathode 30 is shown in more detail. The adapter 36 can have a generally U-shaped body 38. The body 38 can have an upper wall 40 and opposing side walls 42A, 42B. Specifically, the side wall 42A can extend generally vertically from one end 40A of the upper wall 40, and the side wall 42B can extend generally vertically from the opposing end 40B of the upper wall 40. The side walls 42A, 42B can extend generally vertically from the upper wall 40 in the same direction. Therefore, the side walls 42A, 42B can be spaced apart from each other and face each other.

[0059] Sidewall 42A can have a generally cylindrical bar 44A coupled thereto. Sidewall 42B can similarly have a generally cylindrical bar 44B coupled thereto. Cylindrical bars 44A, 44B can face each other, be generally planar, and can be spaced apart from each other and from upper wall 40.

[0060] The adapter 36 may also include a baffle 46 movably secured within the body 38. For example, a bolt or other fastener 48 may extend through the upper wall 40 into the body 38, and the baffle 46 may be movably secured to the bolt 48. The bolt 48 may be rotated to move the baffle 46 vertically within the body 38 (e.g., the bolt 48 may be rotated in one direction to move the baffle 46 in a downward direction, and the bolt 48 may be rotated in an opposite direction to move the baffle 46 in an upward direction). As discussed herein, a component (such as a dovetail of a blade or vane, etc.) may be secured within the body 38 such that the cylindrical rods 44A, 44B, respectively, contact and retain the dovetail of the blade or vane. The baffle 46 may be made to contact the bottom wall of the dovetail, and may ensure continuous electrical contact between the blade and the adapter 36 during the aqueous coating process.

[0061] Figure 2C An adapter 36 is shown, wherein a blade 50 is fixed to the adapter 36. The blade 50 may be Figure 1 An example of a turbine blade 10 or another blade or bucket is shown. The blade 50 has a dovetail 52 having an axially extending end wall 62. A plurality of serrations or tabs 54A, 56A extend axially from one side (e.g., the pressure side) of the dovetail 52, and a plurality of serrations or tabs 54B, 56B correspondingly extend axially from the other side (e.g., the suction side) of the dovetail 52. The tab 54A may be associated with the valley 60A, 62A, and the tab 56A may be associated with the valley 62A. The tab 54B may similarly be associated with the valley 60B, 62B, and the tab 56B may be associated with the valley 62B. The valleys 60A, 60B may be proximate to the end wall 62 relative to the valleys 62A, 62B, respectively.

[0062] exist Figure 2C In the illustrated example, the blade 50 is suspended from the adapter 36 such that the dovetail 52 of the blade 50 contacts each of the cylindrical rods 44A, 44B, and the baffle 46 contacts the dovetail end wall 62. More specifically, the cylindrical rod 44A extends into the valley 60A and contacts the blade 50. The cylindrical rod 44B also extends into the valley 60B and contacts the blade 50. The baffle 46 can be tightened using bolts 48 so that it contacts and pushes against the end wall 62. The blade 50 can be thus secured to the adapter 36 along with other blades (each of which can also be secured to another adapter of the cathode 30). The cathode 30 (see Figure 2A ) can then be lowered into the aqueous solution along with the blades (eg, blade 50) to coat one or more portions of each blade.

[0063] like Figure 2A As shown in , each adapter 36 is spaced apart from an adjacent adapter 36 by a distance D. In addition, each adapter 36 extends at the same angle A relative to the support rod 32 in the horizontal plane, thereby ensuring that when fixed to the corresponding adapter 36, the component is also maintained at the same angle from the support rod 32 to another component. The distance D and the angle A can affect the energy transfer from the cathode 30 to the anode, and therefore can affect the coating applied to a specific component. Therefore, it may be important to ensure that each adapter 36 is maintained at a distance D from the adjacent adapter 36 and that each adapter 36 extends from the support rod 32 at the same angle A. It will be appreciated by those skilled in the art that the distance D and the angle A can vary depending on the specific application and the component being coated.

[0064] In the prior art, manual manufacturing processes can be used to produce the different parts of the adapter 36. For example, the cylindrical rod 44A can be welded to the adapter 36 by welding the joint 70A (see FIG. Figure 2C ) can be welded to the side wall 42A, and the cylindrical rod 44B can be welded to the side wall 42B via a weld joint 70B. Similarly, the side walls 42A, 42B of the adapter 36 can be welded to the upper wall 40 via weld joints 72A, 72B, respectively. In addition, each adapter 36 can be welded to a corresponding connecting member 34, and each connecting member 34 can be welded to the support rod 32. The various weld joints can introduce stress to the components of the cathode 30. Over time, as additional components are fixed to the adapter 36 and coated in the aqueous solution, the weld may begin to deform. The deformation of the weld can adversely affect the integrity of the connection of the adapter 36 to the corresponding components, thereby adversely affecting the coating process.

[0065] Figure 3A and Figure 3B The types of defects that may be introduced into a prior art cathode 30 over time are illustrated. Figure 3A A prior art cathode 30' is shown with a support rod 32' and an adapter 36'. The cathode 30' may be an example of a cathode 30 after the cathode 30 has been used to coat a component over a number of cycles. Corresponding reference numerals are used to indicate corresponding portions of the cathode 30 and the cathode 30'. It can be seen that the rigors of the coating process have deformed the alignment of the adapters 36' such that each adapter 36' is no longer at the same angle (e.g., Figure 2A Angle A) in the figure extends from the support rod 32'.

[0066] Figure 3B Adapter 36 is shown. Adapter 36" may be an example of adapter 36 after adapter 36 has been used to coat multiple parts. Blade 50 (see Figure 2C ) and in particular its dovetail 52 is fixed in the adapter 36". Corresponding reference numerals are used to indicate corresponding parts of the adapter 36 and the adapter 36". As illustrated, the adapter 36" has been deformed relative to the adapter 36. For example, the side walls 42A", 42B" are no longer perpendicular to the upper wall 40". In addition, the cylindrical rods 44A", 44B" are no longer aligned with each other.

[0067] Defects (such as Figure 3A and Figure 3B Defects such as those shown, etc., may reduce the efficacy of the aqueous coating process. Since manual manufacturing techniques (e.g., welding) used to manufacture the prior art cathode 30 and adapter 36 may not withstand repeated use of the cathode 30 and adapter 36 in an electrically driven aqueous coating process, one or more of these defects may be introduced over time.

[0068] Another disadvantage of the prior art cathode 30 (e.g., its adapter 36) is that it is easy to damage or damage the components fixed to the adapter 36. As described above, the bolt 48 is usually rotated (e.g., manually using a tool) to make the baffle 46 (see Figure 2B ) is moved to ensure contact between the baffle 46 and the component. If the bolts 48 are not properly tightened, the baffle 46 may not contact the component for the duration of the coating process, thereby affecting the electrolysis process. In order to increase the likelihood of continued contact between the baffle 46 and the component, the bolts 48 may be over-tightened. This may cause the baffle 46 or other portions of the adapter 36 to penetrate into the component and introduce cuts, scratches, or dents therein. As a result, the component may have to be discarded, which may unnecessarily increase the time and cost spent coating a given number of components. It may be desirable to have a more resilient cathode whose components (e.g., adapters) do not deform due to repeated use.

[0069] Figure 4 A cathode 100 according to certain embodiments of the present disclosure is shown. The cathode 100 has a support rod 102. The support rod 102 can be made using a conductive material such as a metal. In certain embodiments, the support rod 102 can be made using titanium (e.g., Ti-64), stainless steel, or another suitable metal. In some examples, a support rod 32 of the prior art can be used (e.g., the connecting member 34 and its adapter 36 can be removed and replaced with a tool made using the technology disclosed herein).

[0070] Support rod 102 can include multiple openings 104. Each opening 104 can be configured to be used for installing tool 200, and tool 200 is used to keep parts in water-based coating process. Components can be aviation components (for example, blades or blades) or components for land-based power generation systems or turbines, including but not limited to airfoils, turbine blades, compressor or fan blades, turbine blades, compressor blades or other suitable components or parts thereof. Components can also be in the automotive industry, in the components used in offshore industries or any other suitable components to be coated via an electric drive water-based process.

[0071] Figure 5The tool 200 is shown in more detail. The tool 200 may include a bracket 210, an adapter 230, and a shaft 290. Each of these components is described in more detail herein. In one aspect, the tool 200 can be manufactured using an additive process. As described herein, certain features of the tool 200 (e.g., its cantilever beam) can be manufactured using only an additive process. In addition, the tool 200 can be more durable and can provide increased coating efficiency relative to the conventionally manufactured prior art adapter 36. In some embodiments of the present invention, the additive process can be or can include laser powder bed fusion. In some embodiments of the present disclosure, the additive process can include selective laser melting (SLM), direct metal laser sintering (DMLS), direct metal laser melting (DMLM), or other suitable additive processes.

[0072] Fig. 6A and Figure 6B The bracket 210 of the tool 200 is shown in more detail. The bracket 210 may be generally an L-shaped bracket having an alignment wall 212 and a support wall 214 extending generally perpendicular to each other. The alignment wall 212 and the support wall 214 may also be referred to herein as a first wall 212 and a second wall 214, respectively.

[0073] The support wall 214 may include a socket or receptacle 216 that may extend from the support wall 214 in the same direction as the alignment wall 212. The socket 216 may have an outer surface 218 and an inner surface 220. The outer surface 218 of the socket 216 may be generally cylindrical and bound the inner surface 220. The inner surface 220 may have an opening or passage 222 defined therein that is configured to receive one end of the shaft 290, as discussed herein. Fig. 6A As shown, the channel 222 may extend through the support wall 214 .

[0074] In some examples, the channel 222 may not be symmetrical or regular (e.g., may not be completely cylindrical). For example, in the illustrated embodiment, the channel 222 is defined by five sides 224A-224E, and the side 224E is shown as being curved. Figure 5 , Fig. 7A as well as Figure 7B) can have an asymmetric shape that is complementary to the shape of the channel 222, such that the end of the shaft 290 can be slidably received within the channel 222. The irregular shape of the channel 222 can be a fail-safe or error-proofing feature, sometimes referred to as a "error-proofing" mechanism, which can ensure that the shaft 290 can only be received in the channel 222 in one way (i.e., the proper orientation). In certain embodiments of the present disclosure, the channel 222 can take other shapes (e.g., other irregular shapes), and the shaft 290 can be configured to fit within the channel 222 only in the correct orientation. As described herein, this can ensure that the adapters 230 extend at the desired angle in the horizontal plane, and that all adapters 230 extend at the same angle.

[0075] Fig. 7A and Figure 7B The adapter 230 is shown in more detail. The adapter 230 can have an upper wall 232. A rear wall 234 and two opposing side walls 236, 238 can extend generally vertically in the same direction (e.g., downward) from the upper wall 232. The side walls 236, 238 may also be referred to herein as a first side wall and a second side wall, respectively.

[0076] The first sidewall 236 can have a bottom side 240. A first tangential rod 242 can be provided at the bottom side 240. The first tangential rod 242 can be generally cylindrical (e.g., can be frustoconical) and can extend inwardly toward the second sidewall 238. The second sidewall 238 can have a bottom side 244. A second tangential rod 246 can be provided at the bottom side 244. The second tangential rod 246 can be generally identical to the first tangential rod 242 and can extend inwardly toward the first sidewall 236. In certain embodiments of the present disclosure, the first tangential rod 242 and the second tangential rod 246 can extend in the same vertical plane and face each other.

[0077] The upper wall 232, the first side wall 236 and the first tangential rod 242, the second side wall 238 and the second tangential rod 246, and the rear wall 234 may collectively define a channel or slot 248. The slot 248 may be configured to receive a component or a portion thereof for an electrically driven aqueous coating process (e.g., configured to receive a dovetail of a gas turbine blade).

[0078] The cantilever or floating plate 250 may extend from the rear wall 234 into the slot 248. In certain embodiments of the present disclosure, the cantilever plate 250 may be spaced apart from the upper wall 232 and may not contact either the first side wall 236 or the second side wall 238. A cantilever plate, such as the cantilever plate 250, may be manufactured integrally with the adapter 230 without using conventional manufacturing techniques (e.g., welding and machining). Additive manufacturing may allow the cantilever plate 250 to be manufactured integrally with the adapter 230. The integral construction may ensure that the cantilever plate 250 does not deform after repeated use.

[0079] The upper wall 232 may have a threaded nut 252 formed as a portion thereof. The threaded nut 252 may be configured to receive a bolt 254 having corresponding threads (see Fig.11A and Fig. 11B As discussed herein, the bolt 254 may be rotated within the threaded nut 252 and caused to push downwardly on the cantilever plate 250 .

[0080] The shaft 290 can be fixed to the adapter 230, and specifically to the upper wall 232 thereof. More specifically, the shaft 290 can have a first end portion 292A and a second end portion 292B, and the second end portion 292B can be fixed to the upper wall 232. In many aspects, the second end portion 292B can be integral with the upper wall 232 and permanently fixed to the upper wall 232. For example, the adapter 230 and the shaft 290 can be additively manufactured together as a single piece. The first end portion 292A of the shaft 290 can be configured to be matingly received in the socket 216 of the bracket 210 (see Figure 6B ) in channel 222.

[0081] As noted, the bracket 210 can be manufactured using additive manufacturing. The adapter 230 along with the shaft 290 can also be manufactured as a unitary device using additive manufacturing. The bracket 210 and the adapter 230 and shaft 290 can each be manufactured using a conductive material such as titanium (e.g., Ti-64) or other suitable materials. Fig. 8A and Figure 8B The cover 300 shown in more detail in FIG. 1 can also be manufactured using an additive process. In certain embodiments of the present disclosure, the cover 300 can be made of a polymer. Making the cover 300 with a polymer can reduce the possibility of the cover 300 being scored, scratched, or dented when the cover 300 contacts it.

[0082] The cover 300 may have a first side wall 302, a second side wall 304, and a front wall 306 (see Fig. 8A and Figure 8B ). The first side wall 302 may extend substantially perpendicularly from one end of the front wall 306 , and the second side wall 304 may extend substantially perpendicularly from the other end of the front wall 306 .

[0083] The first sidewall 302 can have a first planar or substantially planar portion 308 and a first contoured portion 310. The second sidewall 304 can also have a second planar or substantially planar portion 312 and a second contoured portion 314. The first planar portion 308 and the second planar portion 312 can face each other. The first contoured portion 310 and the second contoured portion 314 can also face each other.

[0084] The first planar portion 308 of the first side wall 302 can have a notch 316 extending from a distal end (i.e., an end farthest from the front wall 306). The second planar portion 312 can similarly have a notch 318 extending from its distal end. The notches 316, 318 can extend toward each other and face each other. The cover 300 can be adapted to fit over and cover the adapter 230 (e.g., when the component is held by the adapter 230). More specifically, as discussed further below, the cover 300 can be configured to be assembled on the adapter 230 after the component to be coated is fixed in the adapter 230 to ensure that the component does not move relative to the adapter 230.

[0085] Fig. 9 The cover 300 is shown after it has been slid onto the adapter 230 (for clarity, Fig. 9 The adapter 230 is not shown together with the components for coating). It can be seen (see also Figure 7A-7B and Figure 8A-8B ), the cover 300 is assembled on the adapter 230 so that the first side wall 302 of the cover 300 is adjacent to and in contact with the first side wall 236 of the adapter 230, and the second side wall 304 of the cover is adjacent to and in contact with the second side wall 238 of the adapter 230. When the cover 300 is slid on the adapter 230 in this manner, the notches 316 and 318 can respectively engage the rear wall 234 of the adapter 230 and ensure that the cover 300 is movably fixed relative to the adapter 230.

[0086] Fig.10 An adapter 230 is shown in which the blade 50 (see Figure 2C ) is fixed to the adapter 230 for coating. A cover 300 is also shown that interfaces with the adapter 230 and the blade 50.

[0087] In more detail, the dovetail 52 of the blade 50 may slide into the slot 248 defined by the upper wall 232, the first side wall 236 and the first tangential rod 242, the second side wall 238 and the second tangential rod 246, and the rear wall 234 of the adapter 230. When the dovetail 52 is thus slid within the slot 248, the first tangential rod 242 may be adjacent to the valley 60A and may contact one or both surfaces forming the valley 60A. Similarly, the second tangential rod 246 may be adjacent to the valley 60B and may contact one or both surfaces forming the valley 60B.

[0088] Thereafter, the cover 300 may be slid onto the adapter 230 and the dovetail 52 of the blade 50. As described above, the notches 316, 318 (see Figure 8B) can engage the rear wall 234 of the adapter 230. In addition, the contoured portion 310 of the cover 300 can engage the tabs 54A, 56A and the valley 62A, and the contoured portion 314 of the cover 300 can engage the corresponding tabs 54B, 56B and the valley 62B. Therefore, the cover 300 can ensure that the blade 50 is firmly fixed to the adapter 230 with minimal or no relative movement between the adapter 230 and the blade 50.

[0089] like Fig.10 As shown, the cantilever plate 250 may be on top of and adjacent to the end wall 62 of the dovetail 52 when the blade 50 is secured to the adapter 230 . Fig.11A and Fig. 11B The interaction of the cantilever plate 250 with the end wall 62 of the dovetail 52 is shown in more detail. Fig.11A As shown, the bolts 254 are not tightened and, therefore, the cantilever plate 250 is spaced apart from the dovetail end wall 62 . Fig. 11B The bolts 254 are shown having been rotated to push the cantilever plate 250 toward the dovetail end wall 62. The cantilever plate 250 is thus in contact with the dovetail end wall 62. The bolts 254 can ensure that the cantilever plate 250 remains in contact with the dovetail end wall 62, which can ensure continuous and consistent electrical contact between the adapter 230 and the blade 50 during the aqueous coating process without causing any damage to the blade 50.

[0090] Focus Point Fig.13 (See also Figures 12A-12F ) to illustrate a method 400 for making and using a cathode 100 having a plurality of tools 200 to coat a component using an electrically driven aqueous process.

[0091] At step 402, a cathode support rod 102 may be obtained. For example, Fig. 12A As shown, cathode support rods 102 may be obtained that include titanium or another suitable material. Support rods 32 of prior art cathodes 30 may also be obtained and modified in accordance with the disclosure herein.

[0092] At step 404, a plurality of openings 104 may be introduced into the support rod 102, such as Fig. 12B Each opening 104 may be sized to receive a socket 216 of a bracket 210 (see Figure 6B ), and specifically, the outer surface 218 of the socket 216.

[0093] At step 406, tool 200 (i.e., bracket 210, adapter 230, and shaft 290) and cap 300 may be manufactured using additive manufacturing. For example, bracket 210, adapter 230, and shaft 290 may be additively manufactured using titanium, and cap 300 may be additively manufactured using one or more polymers. Adapter 230 and shaft 290 may be additively manufactured as a unitary piece. Step 406 may be performed before step 404, before step 402, or simultaneously or partially simultaneously with steps 402, 404. Further, various parts of tool 200 may be manufactured simultaneously or generally simultaneously or may be manufactured at different times.

[0094] In some applications, it may be necessary to coat multiple similar parts (e.g., multiple blades, impellers, or aerospace parts or other parts). In these applications, multiple similar tools 200 and covers 300 may be manufactured using additive manufacturing at step 406. For example, where three parts are to be coated, three tools 200 and three covers 300 may be manufactured (e.g., together or separately) to allow the three parts to be coated simultaneously.

[0095] like Fig. 12C As shown, at step 408, the support wall 214 of each bracket 210 of each tool 200 can be located on the top of the support rod 102 so that the socket 216 of each bracket 210 passes through an opening 104 in the support rod 102 (see also Figure 6B ). When the support wall 214 of the bracket 210 is thus located on the top of the support rod 102, the alignment wall 212 of the bracket 210 can be adjacent to the support rod 102 and contact the support rod 102. Each alignment wall 212 of the bracket 210 (see Figure 6B ) can be located on the same side of the support rod 102, thereby ensuring that each bracket 210 is oriented in the same manner (and therefore the channel 222 of each socket 216 is oriented in the same manner to receive the shaft 290 of the adapter 230).

[0096] like Fig.12D As illustrated, at step 410, the shaft 290 of each adapter 230 can be received in the socket 216 of one of the brackets 210, and specifically in the channel 222 thereof. The fail-safe feature of each channel 222 can ensure that the shaft 290 of each bracket 210 is oriented in the same manner, and thus, each adapter 230 extends at the same angle B in the horizontal plane relative to the support rod 102. In some applications, each bracket 210 of each tool 200 can be fixed to the support rod 102, for example, it can be welded to the support rod or fixed using an adhesive or via other suitable means. This can permanently attach the tool 200 (i.e., the bracket 210 together with the shaft 290 and the adapter 230) to the support rod 102. The cathode 100 (see Figure 4) can now be completed.

[0097] In step 412, if Fig.12E As shown, each of the components to be coated (in this example, the blades 50) can be fixed to one of the adapters 230. More specifically, the dovetail 52 of each blade 50 can be slid into the groove 248 defined by the upper wall 232, the first side wall 236 and the first tangential rod 242, the second side wall 238 and the second tangential rod 246, and the rear wall 234 of one adapter 230 (see also Fig.10 ), so that the blade 50 is retained by the adapter 230. When the dovetail 52 is thus slid within the slot 248, the first tangential rod 242 may be adjacent to the valley 60A and the second tangential rod 246 may be adjacent to the valley 60B. Each blade 50 to be coated may now be oriented in the same manner as the other blades 50.

[0098] In step 414, if Fig.12F As shown, a cover 300 may be secured to each adapter 230 and to the dovetail 52 of the blade 50 associated with the adapter 230. Fig.10 As discussed, the profile portion 310 of the cover 300 can engage the tabs 54A, 56A and the valley 62A, and the profile portion 314 of the cover 300 can engage the corresponding tabs 54B, 56B and the valley 62B. Thus, the cover 300 can ensure that the blade 50 is securely fixed to the associated adapter 230 with minimal or no relative movement between the adapter 230 and the blade 50.

[0099] At step 416, a bolt 254 may be coupled to the threaded nut 252 of each adapter 230 (see Fig. 11B ) and is tightened so that the cantilever plate 250 contacts the end wall 62 of the dovetail 52 of each blade 50. The cantilever plate 250 can ensure continuous electrical contact between the adapter 230 and the blade 50 without breaking or otherwise damaging the blade 50. In some examples, step 416 can be performed before step 414 (i.e., the cantilever plate 250 can first be brought into contact with the end wall 62 of the dovetail 52, and then the cover 300 can be slid onto the adapter 230 and the dovetail 52).

[0100] At this point, the assembly of the blades 50 to be coated with the cathode 100 may be complete. At step 418, the cathode 100 together with the associated tool 200 and blades 50 may be lowered into the aqueous solution. The cathode 100 and anode may interact in the aqueous solution and the transfer of energy may cause each blade 50 to be uniformly coated.

[0101] Once the blades 50 have been coated as desired, at step 420, the cathode 100 may be removed from the aqueous solution, the cover 300 may be slid out of the associated adapter 230, and each blade 50 may be disassociated from the associated tool 200. The coated blades 50 may now be ready for use, or may undergo additional processing (e.g., undergo a post-processing process such as machining) prior to use.

[0102] When another batch of blades 50 is to be coated, the method 400 may return to step 412 where each blade 50 in the new batch may be secured to one of the adapters 230 as discussed herein. The cathode 100 together with the tool 200 may be used in this manner to coat a plurality of blades 50 using an electrically driven aqueous process. It has been found that the adapter 36 ( Figure 2B ), the additively manufactured tools 200 are less prone to deformation and can be used to coat a much larger number of blades 50. In addition, the additively manufactured tools 200 can exhibit much lower electrical resistance relative to their prior art counterparts manufactured using conventional techniques due to their integral and uniform construction; therefore, the tools 200 can allow the blades 50 to be coated more efficiently using an electrically driven coating process relative to the prior art adapters 36.

[0103] Although the tool 200 shown can be used to coat blades and vanes of a gas turbine, it will be understood by those skilled in the art that this is exemplary only. The techniques described herein can be used in additive manufacturing tools (e.g., additive manufacturing tools with cantilever plates) for coating many different types of parts (e.g., parts used in the automotive industry, in the offshore industry, or any other suitable parts to be coated by an electrically driven waterborne process). In some examples, the tool 200 can be used for platinum electroplating or other suitable coating processes. In other examples, a tool with a cantilever plate as described herein can be used to secure parts for any suitable treatment process.

[0104] The airfoil of a gas turbine blade may be coated in its entirety with platinum plating. Other coatings may be applied only to one or more portions of the airfoil. For example, the tip of the airfoil (e.g., tip 28 ( Figure 1 )) Cubic raw nitride (CBN) can be coated for additional wear resistance. In addition to platinum plating, CBN coating can be achieved using an electrically driven waterborne process.

[0105] Fig.14 A prior art adapter 80 that can be used for CBN coating of an airfoil tip is shown. The prior art adapter 80 may have a groove 81 configured to hold a dovetail of a blade. Fig.15As shown, blade 90 has a dovetail 92 having an end surface 94 and a tongue 96. End surface 94 is shown as having a raised detail or feature 98.

[0106] The blade 90 (and specifically its dovetail 92) can be received in the slot 81 of the prior art adapter 80. The bolt 82 of the adapter 80 can pass through the aperture 84 to secure the blade 90 and the adapter 80. The bolt 82 can damage the dovetail 92, such as its raised feature 98 (see the indentation 99 on the raised feature 98). This may make the blade 90 unsuitable for use.

[0107] Other disadvantages associated with the adapter 80 may stem from its conventional construction. Specifically, various surfaces of the adapter 80 (e.g., side walls, cylindrical rods, upper wall, rear wall, etc.) may be welded to one another, and these welds may deform over time when the adapter 80 is repeatedly used in a waterborne coating process. A deformed adapter 80 may not be suitable for use in a waterborne coating process.

[0108] Fig.16 Another tool 500 that can be used to coat parts via an electrically driven aqueous process is shown. The tool 500 can include a body 502 having side walls 504, 506, an upper wall 508, and a rear wall 510.

[0109] The slot 515 may be defined by the rear wall 510, the side walls 504, 506, and the inner surfaces of the upper wall 508. The cantilever plate 514 may extend from the rear wall 510 within the slot 515. The dovetail 92 of the blade 90 may be slid into the slot 515 so that the blade 90 is retained by the tool 500. The inner surfaces 504I, 506I of the side walls 504, 506 may be shaped to matingly receive the tab 96 of the dovetail 92 of the blade 90, respectively. The cantilever plate 514 may contact the end surface 94 of the dovetail 92. In certain embodiments of the present disclosure, the body 502 may have one or more threaded openings (e.g., Fig.17 516 in the body), a corresponding member may pass through one or more threaded openings to facilitate fixation of the blade 90 and the tool 500. Another opening (e.g., opening 518) may be provided in the body to allow an electrical connection member to connect the tool 500 to the tip.

[0110] Unlike tool 200, tool 500 may not require a cover (e.g., cover 300) to secure the blade to tool 500. This may be because the contoured inner surfaces 504I, 506I may interface with multiple pairs of tabs 96 and thus make additional tools for securing the blade and tool 500 unnecessary.

[0111] According to tool 200, tool 500 can be manufactured using additive manufacturing. One advantage of using additive manufacturing to manufacture tool 500 can be the ability to integrally manufacture cantilever plate 514 to accommodate raised features 98 of end surface 94. Specifically, as Fig.16 514, cantilever plate 514 can be manufactured to include recessed portions 520 that correspond to raised features 98 on end surface 94 of dovetail 92. Blades 90 can thus be slid into slot 515 and securely held by tool 500 without breaking or otherwise damaging blades 90 despite the presence of raised features 98. Thus, tool 500 can be used to coat multiple blades 90 over time without damaging any blades 90. Tools 500 manufactured using additive manufacturing techniques can be more durable and can produce more effective coatings relative to adapters 80 manufactured using welding and other conventional techniques.

[0112] Although the tool 500 illustrated herein is described with reference to a blade, those skilled in the art will appreciate that other tools manufactured using additive manufacturing techniques (e.g., tools having cantilever beams) may be manufactured to accommodate and coat other components using an electrically driven aqueous process.

[0113] Some non-exhaustive implementation examples are described below.

[0114] In an implementation, a method for securing a component for a process includes obtaining a tool for holding the component during the process. The tool includes a cantilever plate. The method includes associating the tool with a support rod and securing the component to the tool such that the cantilever plate contacts the component.

[0115] In some implementations, according to any of the preceding implementations, a tool includes a bracket and an adapter connectable by a shaft.

[0116] In some implementations, according to any of the preceding implementations, the cantilever plate extends from a rear surface of the adapter, and the shaft and adapter are additively manufactured as a unitary structure.

[0117] In some implementations, according to any of the preceding implementations, the bracket includes a socket having a channel.

[0118] In some implementations, according to any of the preceding implementations, the receptacle is accessible through an opening in the support rod.

[0119] In some implementations, according to any of the preceding implementations, the channel comprises an asymmetric shape and is configured to receive the shaft in only one orientation.

[0120] In some implementations, according to any of the preceding implementations, the method includes obtaining a cover configured to slide over the tool.

[0121] In some implementations, according to any of the preceding implementations, the method includes rotating the rotatable member to cause the cantilever plate to contact the component.

[0122] In some implementations, according to any of the preceding implementations, the method includes lowering a support rod and a component secured to a tool in an aqueous solution to coat the component using an electrically driven aqueous process.

[0123] In some implementations, according to any of the preceding implementations, the method includes associating a second tool with the support rod, and the tool and the second tool extend from the support rod at a same angle.

[0124] In some implementations, according to any of the preceding implementations, the tool includes an adapter configured to retain a dovetail of a blade of a gas turbine.

[0125] In some implementations, according to any of the preceding implementations, the adapter includes two opposing cylindrical bars, and each opposing cylindrical bar is configured to interface with a dovetail joint.

[0126] In some implementations, a tool for securing a component for a process is disclosed. The tool includes a bracket and an adapter, the bracket including a socket having a channel, the adapter including a body, and the body including a cantilever plate. The adapter is configured to receive the component for the process. The tool includes a shaft configured to be received in the channel for coupling the adapter to the bracket.

[0127] In some implementations, according to any of the preceding implementations, the adapter includes a bolt passing through the body and coupled to the cantilever plate.

[0128] In some implementations, according to any of the preceding implementations, the channel includes an asymmetric shape, and the shaft has a shape corresponding to the shape of the channel.

[0129] In some implementations, according to any of the preceding implementations, the processing process is an electrically driven aqueous process, the bracket is coupled to the support rod, and the adapter is manufactured using an additive process so that the body and the cantilever plate have a unitary structure.

[0130] In some implementations, according to any of the preceding implementations, the tool includes a polymer cover configured to slide over the adapter.

[0131] In some implementations, a method for coating an aerospace component using an electrically driven aqueous process is disclosed. The method includes obtaining an additively manufactured tool for holding an aerospace component during an electrically driven aqueous process. The tool includes: an adapter having a cantilever plate; a bracket having a socket having a channel; and a shaft coupled to the adapter and receivable within the socket to couple the adapter to the bracket. The method includes: securing the aerospace component to the adapter so that the cantilever plate contacts the aerospace component; coupling the adapter to the bracket via the shaft; and associating the bracket with a cathode rod.

[0132] In some implementations, according to any of the preceding implementations, the aerospace component includes a dovetail, the dovetail includes an end wall, and the cantilever plate contacts the end wall of the dovetail of the aerospace component.

[0133] In some implementations, according to any of the preceding implementations, the adapter includes two opposing cylindrical rods to engage the dovetail during the electrically driven aqueous process.

[0134] Without departing from the spirit and scope of the present disclosure, many different arrangements of the various components depicted and components not shown are possible. The embodiments of the present disclosure have been described with illustrative, but not restrictive, intent. Alternative embodiments that do not depart from the scope thereof will become clear to those skilled in the art. Those skilled in the art may develop alternative means for implementing the aforementioned improvements without departing from the scope of the present disclosure.

[0135] It should be understood that certain features and subcombinations are of utility and may be employed without reference to other features and subcombinations and are contemplated to be within the scope of the claims. Not all steps listed in the various figures need to be performed in the particular order described.

Claims

1. A method for fixing a component for a processing process, the method comprising: obtaining a tool for holding the component during the processing, the tool comprising a cantilever plate; associating the tool with a support rod; as well as The component is secured to the tool such that the cantilever plate is in contact with the component.

2. The method according to claim 1, wherein: The tool comprises a bracket and an adapter connectable by a shaft.

3. The method according to claim 2, wherein: The cantilever plate extends from a rear surface of the adapter; and The shaft and the adapter are additively manufactured as a unitary structure.

4. The method according to claim 3, wherein: The bracket includes a socket having a channel.

5. The method according to claim 4, wherein: The socket is accessible through an opening in the support rod.

6. The method according to claim 4, wherein: The channel has an asymmetric shape and is configured to receive the shaft in only one orientation.

7. The method according to claim 1, wherein: The method further includes obtaining a cover configured to slide over the tool.

8. The method according to claim 1, wherein: The method further includes rotating a rotatable member to cause the cantilever plate to contact the component.

9. The method according to claim 1, wherein: The method further includes lowering the support rod and the component secured to the tool into an aqueous solution to coat the component using an electrically driven aqueous process.

10. The method according to claim 9, wherein: The method further includes associating a second tool with the support rod; and wherein the tool and the second tool extend from the support rod at the same angle.

11. The method according to claim 10, wherein: The tool includes an adapter configured to retain a dovetail of a blade of a gas turbine.

12. The method according to claim 11, wherein: The adapter includes two opposing cylindrical bars, each of which is configured to interface with the dovetail joint.

13. A tool for fixing a component for a processing process, the tool comprising: a bracket, the bracket including a socket having a passage; an adapter including a body including a cantilever plate, the adapter being configured to receive a component for the treatment process; as well as A shaft is configured to be received within the channel for coupling the adapter to the bracket.

14. The tool according to claim 13, wherein: The adapter includes a bolt passing through the body and coupled to the cantilever plate.

15. The tool of claim 13, wherein: The channel comprises an asymmetric shape; and The shaft has a shape corresponding to the asymmetric shape of the channel.

16. The tool of claim 13, wherein: The treatment process is an electrically driven water-based process; The bracket is coupled to a support rod; and The adapter is manufactured using an additive process so that the body and the cantilever plate have an integral structure.

17. The tool of claim 13, further comprising a polymer cover configured to slide over the adapter.

18. A method for coating an aerospace component using an electrically driven waterborne process, the method comprising: Obtaining an additively manufactured tool for holding the aerospace component during the electrically driven aqueous process, the tool comprising: an adapter having a cantilever plate, a bracket having a socket having a channel, and a shaft coupled to the adapter and receivable within the socket to couple the adapter to the bracket; securing the aerospace component to the adapter such that the cantilever plate contacts the aerospace component; coupling the adapter to the bracket via the shaft; and The bracket is associated with the cathode rod.

19. The method according to claim 18, wherein: The aerospace component includes a dovetail including an end wall, and wherein the cantilever plate contacts the end wall of the dovetail of the aerospace component.

20. The method according to claim 19, wherein: The adapter includes two opposing cylindrical rods configured to engage the dovetail during the electrically driven aqueous process.

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