Masking system, masking system for additive manufacturing, and method for masking parts

Abstract

The present invention provides a masking system, an additively manufactured masking system, and a method for masking a component, wherein the masking system is used to mask a component for a media jetting process. The masking system has a first part and a second part, each of which is manufactured in an additive manner. The first part has a holding part, a processing part, and a receiving member. The holding part has a placement area. The receiving member is configured to operably receive a fluid distribution device. The second part has a second holding part including a second placement area. The second part is configured to be fixed to the first part so that the component is placed in the placement area and the second placement area, and at least a portion of the component is masked by the first part and the second part.

Description

Technical Field

[0001] The present disclosure relates generally to the field of masking systems. More specifically, the present disclosure relates to masking systems for masking additive manufacturing of parts for media jetting processes. 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 aspects of the present disclosure, a masking system for masking a component for a media jetting process is provided. The masking system has a first portion and a second portion, each manufactured in an additive manner. The first portion has a holding portion, a processing portion, and a receiving member. The holding portion has a placement area. The receiving member is configured to operably receive a fluid distribution device. The second portion has a second holding portion including a second placement area. The second portion is configured to be fixed to the first portion so that the component is placed in the placement area and the second placement area, and at least a portion of the component is masked by the first portion and the second portion.

[0004] In one aspect, according to any of the preceding aspects, the first portion and the second portion are each additively manufactured using an elastomeric material.

[0005] In one aspect, according to any of the preceding aspects, the seating area and the second seating area are collectively configured to hold the component in only one component orientation.

[0006] In one aspect, according to any of the preceding aspects, the retaining portion comprises an outer section having a channel.

[0007] In one aspect, according to any of the preceding aspects, the second retaining portion comprises a second outer section having a second channel.

[0008] In one aspect, according to any of the preceding aspects, when the first part is secured to the second part, the channel and the second channel are coplanar.

[0009] In one aspect, according to any of the preceding aspects, one of the first part and the second part comprises a locking member.

[0010] In one aspect, according to any of the preceding aspects, the locking member is configured to be received within a recess of one of the first and second parts comprising the other of the locking member.

[0011] In one aspect, according to any of the preceding aspects, the first portion comprises a ridge and the second portion comprises a notch corresponding to the ridge.

[0012] In one aspect, according to any of the preceding aspects, the component is a blade of a gas turbine.

[0013] In one aspect, according to any of the preceding aspects, the media blasting process is a sandblasting process.

[0014] In one aspect, according to any of the preceding aspects, the receiving member is threaded and is positioned within the processing portion.

[0015] In one aspect of the present disclosure, a masking system for masking additive manufacturing of a blade for a media jetting process is provided. The masking system includes a first portion and a second portion that can be fixed to the first portion. The first portion and the second portion are configured to hold the blade together so that only a target surface of the blade is exposed. The first portion and the second portion are separately manufactured in an additive manner. The masking system is configured to operably receive a fluid dispensing device for dispensing a fluid during the media jetting process.

[0016] In one aspect, according to any of the preceding aspects, the first portion and the second portion are each additively manufactured using an elastomeric material.

[0017] In one aspect, according to any of the preceding aspects, the first part is configured to be coupled to the second part without the use of any tools.

[0018] In one aspect of the present disclosure, a method of masking a component includes: obtaining an additively manufactured masking device having a first portion and a second portion. The method includes operably coupling a fluid dispensing device to the masking device. The method includes securing the first portion to the second portion such that the component is retained by the first portion and the second portion and only a target surface of the component is exposed. The method includes operating the fluid dispensing device to dispense a fluid into the component.

[0019] In one aspect, according to any of the preceding aspects, the first part and the second part are additively manufactured using a photopolymerization curing technique.

[0020] In one aspect, according to any of the preceding aspects, the first portion comprises a chamber having a receiving member for operably receiving a fluid dispensing device.

[0021] In one aspect, according to any of the preceding aspects, the first portion and the second portion each have a respective recessed portion configured to collectively retain a component.

[0022] In one aspect, according to any of the preceding aspects, the method includes media jetting the target surface while the fluid dispensing device dispenses the fluid into the component.

[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 embodiments 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, and in which:

[0025] Figure 1 It is a three-dimensional image of a turbine blade.

[0026] Figure 2 is a perspective view of a masking system according to some aspects of the present disclosure.

[0027] Figure 3 yes Figure 2 A perspective view of the masking system with the vanes retained for media injection.

[0028] Figure 4A yes Figure 2 A perspective view of a first part of a masking system.

[0029] Figure 4B yes Figure 2 Front view of the first part of the masking system.

[0030] Figure 4C yes Figure 2 Rear view of the first part of the masking system.

[0031] Figure 5 It is along Figure 4B A cross-sectional view taken along line 5-5.

[0032] Fig. 6A The fluid distribution device and Figure 2 A schematic diagram of the operative connections of a first portion of a masking system.

[0033] Figure 6B The medium is sprayed to maintain Figure 2 Schematic diagram of a fluid distribution device distributing fluid into the masking system while on the surface of a blade within the masking system.

[0034] Fig. 7A yes Figure 2 A perspective view of the second part of the masking system.

[0035] Figure 7B yes Figure 2 Front view of the second part of the masking system.

[0036] Fig. 8A The closed position is shown Figure 2 A stereogram of the masking system.

[0037] Figure 8B The closed position is shown Figure 2 Bottom view of the shielding system.

[0038] Fig. 9 is a schematic diagram illustrating another masking system according to an aspect of the present disclosure.

[0039] Fig. 10A yes Fig. 9 A perspective view of a first part of a masking system.

[0040] Fig. 10B yes Fig. 9 A perspective view of the second part of the masking system.

[0041] Fig.11A Shows Fig. 9 A side view of a first locking member of a second portion of a masking system, the first locking member interlocking with a first recess of the first portion.

[0042] Fig. 11B Shows Fig. 9 A side view of a second locking member of a second portion of a masking system, the second locking member interlocking with the second recess of the first portion.

[0043] Fig.12 It is a diagram showing the manufacture and use of Figure 2 and Fig. 9 A flow chart of a method of masking a system. DETAILED DESCRIPTION

[0044] A gas turbine engine typically includes a multi-stage compressor coupled to a multi-stage turbine via an axial shaft. Air enters the gas turbine engine through the compressor, and its temperature and pressure increase as the air passes through the rear stage of the compressor. The compressed air is then directed to one or more combustors, where it is mixed with a fuel source to produce a combustible mixture. The mixture is ignited in the combustor to produce a stream of hot combustion gases. These gases are directed into the turbine, causing the turbine to rotate, thereby driving the compressor. The output of the gas turbine engine can be mechanical thrust via exhaust from the turbine or shaft power from the rotation of the axial shaft, where the axial shaft can drive a generator to produce electricity.

[0045] The compressor and turbine each include a plurality of rotating blades and stationary vanes having airfoils extending into the compressed air flow or hot combustion gas flow. Each blade or vane has a specific set of design criteria that must be met to provide the necessary work for the flow through the compressor and turbine. However, due to the harsh nature of the operating environment, particularly in turbines, it is often necessary to cool these blades and vanes. The blades and vanes typically utilize complex internal cooling passages in order to maximize the efficiency of the cooling fluid passing therethrough.

[0046] Figure 1 A gas turbine component, such as a gas turbine blade 10, is shown. 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 serrated protrusions 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.

[0047] The airfoil 12 may have a pressure side 26, a suction side 27 opposite to the pressure side 26, and a tip 28. The tip 28 may include or may be configured to interact with a shroud. The shroud may be disposed at the tip 28 of each blade 10 or may be a fixed ring including one or more circumferentially extending segments, each circumferentially extending segment being connected to the gas turbine casing. The shroud may be configured to seal the gap between the tip of the blade 10 and the fixed component (e.g., stator) of the turbine, and thereby reduce the leakage flow between the rotating component and the fixed component. The airfoil 12 (e.g., its pressure side 26) may be in contact with the combustion gas at an extremely high temperature. The airfoil 12 or a portion 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.

[0048] The bottom wall 25 of the dovetail 18 may include one or more air inlet apertures 30. In addition, one or more portions of the blade 10 may include cooling holes 32 for cooling the blade 10 during operation. The cooling holes 32 may be disposed on one or more surfaces of the airfoil 12, such as the pressure side 26, the suction side 27, the leading edge, the trailing edge, or a combination thereof. The cooling holes 32 may be circular cooling holes, diffuse (e.g., angled) cooling holes, cooling slots, or one or more other regular or irregular shapes. The cooling gas may pass through an internal cooling passage (not shown for ease of description) in the blade 10 and out of the cooling holes 32 to form a thin film coating on the outer surface of the airfoil 12, thereby preventing direct contact of the hot gas with the surface of the blade 10. For example, the illustrated blade 10 has a plurality of air inlet apertures 30 in the bottom wall 25 of the dovetail 18 and a plurality of cooling holes 32 on the pressure side 26 of the airfoil 12. The blade 10 (including its airfoil 12) may include a hollow internal passage for cooling air to pass through, such as, but not limited to, a hollow internal passage from the air inlet aperture 30 to the cooling hole 32. Thus, cooling air may be exhausted from the compressor and directed into the air inlet aperture 30. The air may exit the cooling hole 32 to cool one or more portions of the blade 10 during operation. Those skilled in the art will appreciate that different blades may have different cooling schemes, and Figure 1 The inlet apertures 30 and cooling holes 32 in FIG. 3 are exemplary only and are not intended to be independently limiting.

[0049] As described above, one or more portions of the blade 10 may be coated with heat-resistant, wear-resistant and / or other suitable coatings. As an example, the airfoil 12 and the gas path side surface 14 of the platform 16 may be coated with one or more layers of coating. The surfaces of the airfoil 12 (i.e., the pressure side 26 and the suction side 27) and the gas path side surface 14 of the platform 16 may be collectively referred to herein as the "gas path surface" of the blade 10. In order to prepare these gas path surfaces of the blade 10 for downstream surface preparation, the gas path surface may be sprayed with a medium. The medium may be one or more of a solid, a liquid or a gas. In many aspects, the medium may be abrasive. For example, the medium may be or may include sand or gravel sprayed onto the gas path surface with an air jet. Alternatively, for example, gravel or sand may be sprayed onto the gas path surface with water. The abrasive medium that is forced to be propelled onto the gas path surface under high pressure may clean these surfaces by removing any contaminants on these surfaces. In some examples, the medium spray may introduce textures to the gas path surface, which may facilitate the downstream surface preparation of these surfaces. For example, the media blasting process can remove paint, rust, sand, scale, or other contaminants from gas path surfaces and activate or otherwise prepare these surfaces to receive coatings or adhesives. Such media blasting processes can also be used to provide a smooth and aesthetically pleasing finish to the gas path surfaces of the blade 10. The surfaces of the component to be media blasted (i.e., those surfaces exposed to the media during the media blasting process) may be referred to herein as the "target surfaces" of the component. Figure 3 In the illustrated example, the target surface of the blade 10 is its gas path surface. In other examples, the target surface of the blade may be different from the gas path surface (eg, may be a subset of the gas path surface or may be one or more other surfaces).

[0050] Components of a gas turbine, such as a blade 10 or a vane, may be blasted with media one or more times during manufacturing or repair. It is not uncommon for one or more portions of a blade or vane (e.g., one or more target surfaces thereof) to be blasted with media four to six times or more. When only a portion of a blade or vane is to be blasted with media, the remaining portion of the blade or vane may be masked to reduce the likelihood that the media will impact the remaining surface of the blade or vane. For example, when the target surface is to be blasted with media, the operator may mask the lower surface 20 and dovetail 18 of the platform 16 with masking tape, or mask these portions of the blade or vane with his or her hands. Alternatively, the blade 10 or vane may be held in a masking fixture that is configured to mask those portions of the blade 10 or vane that are not blasted with media.

[0051] These masking or shielding techniques may not be able to effectively cover the portions of the blade 10 or bucket that are not being media blasted for the entire duration of the media blasting process. For example, covering portions of the blade 10 or bucket (such as the bottom surface 20 of the platform 16 and the dovetail 18, etc.) with masking tape or with the operator's hands may leave one or more openings for media to pass through and undesirably impinge on one or more of these blade 10 or bucket portions. Further, given that a blade or bucket may have many complex features, techniques such as molding for making masking fixtures may not produce a masking fixture that is economically feasible and completely masks those portions of the blade or bucket that are not being media blasted for the entire duration of the media blasting process.

[0052] Other masking or shielding techniques may not exclude media from being stuck in the openings of the blades or vanes. For example, when the airfoil 12 of the blade 10 is sandblasted or grit blasted, the sand or grit may be stuck in the cooling holes 32. After the media blasting process is completed, the airfoil 12 may be sprayed with air in an attempt to dislodge any media stuck in the cooling holes 32. However, the sand or grit may remain stuck in the cooling holes 32 or may be stuck in different cooling holes 32. The sand or grit may damage the blade 10, and additional work may be required to address the damage and prepare the blade 10 for operation. If the blade 10 with sand or grit accumulated in the cooling holes 32 is operably connected to a gas turbine, the blade 10 may overheat, fail prematurely (e.g., melt) during operation and cause significant damage. It may be desirable to have a reusable masking system that effectively masks non-target surfaces of blades, vanes or other components and ensures that the medium does not get stuck in the cooling holes or other openings or cracks of the blades, vanes or other components.

[0053] Focus Pointing Figure 2 , Figure 2 A masking system 100 is shown in accordance with one aspect of the present disclosure. The masking system 100 may also be referred to herein as a conformal masking system 100, a tool-less masking system 100, or a protective cover 100 (hereinafter "masking system 100").

[0054] The masking system 100 may include a first portion (or "base" or "receiver") 102 and a second portion (or "cap" or "cover") 150. For purposes of discussion, it is assumed that the airfoil 12 of the blade 10 and the gas path side surface 14 of the platform 16 (i.e., the target surface) are to be sprayed with a medium, and the remaining portion of the blade 10 (i.e., the non-target surface) is to be masked or shielded to protect these surfaces from being impacted by the medium. As discussed herein and as shown in Figure 3As shown, the blade 10 may be maintained within the masking system 100 such that only its target surface is exposed to the media during the media blasting process. Also as discussed herein, the masking system 100 may reduce or eliminate the possibility of particles of the media accumulating in the blade 10 (eg, in the cooling holes 32 of the airfoil 12).

[0055] Figure 4A , Figure 4B as well as Figure 4C The first portion 102 is shown in greater detail. The first portion 102 can have a holder or holding portion 104 and a handling portion 106. In various aspects, the holding portion 104 can be integral with the handling portion 106 and extend generally upwardly from the handling portion 106. The holding portion 104 can be configured to facilitate retention of the blade 10 in the masking system 100, and the handling portion 106 can allow an operator to handle the masking system 100 as desired.

[0056] The holding portion 104 can have an outer section 108 and an inner section 110 opposite the outer section 108. During the media jetting process, the outer section 108 of the holding portion 104 can be exposed to the media, while the inner section 110 can be isolated from the media. In various aspects, the outer section 108 can be curved. In some examples, the outer section 108 can be substantially semi-elliptical (see Figure 4C ) and may have a first end 110A and a second end 110B (see Figure 4A ). The outer section 108 may have a channel or recess 112 extending from the first end 110A to the second end 110B.

[0057] The inner section 110 can have a receiving or seating area 114 and an outer portion 113 outside the seating area 114. In some examples, the outer portion 113 can surround at least a portion of the seating area 114. The outer portion 113 can have a ridge 116. In some examples, the ridge 116 can be or can include one or more curved portions. For example, as in the example shown, the ridge 116 can be generally U-shaped. In other examples, the ridge can have other symmetrical or asymmetrical shapes (e.g., the ridge can be spherical, rectangular, raised strips, etc.). As discussed herein, the ridge 116 of the first portion 102 can be configured to align with a corresponding complementary recess of the second portion 150 (e.g., Figure 7BThus, the ridge (e.g., ridge 116) can be any suitable component configured to associate (e.g., geometrically interlock) with a corresponding complementary recess (e.g., recess 164). In some examples, the ridge can be disposed on the second portion 150 and the corresponding recess 164 can be disposed on the first portion 102. The opening or hole 117 can be disposed in the outer portion 113 such that the curved ridge 116 is between the opening 117 and the seating area 114.

[0058] The seating area 114 may be generally concave and may include one or more features or protruding members 118 (hereinafter referred to as "features 118") therein. The seating area 114 may be configured to receive or seat the dovetail 18 of the blade 10. The features 118 in the seating area 114 may generally correspond to the serrations or tongues 22 of the dovetail 18 of the blade 10. For example, the features 118 may be configured to mate with the serrations or tongues 22 of the dovetail 18 on one side 23A of the dovetail 18 to the opposite side 23B of the dovetail 18.

[0059] The suction side of the dovetail 18 and its pressure side may be asymmetric. In some examples, features on the suction side of the dovetail 18, such as a serration or tongue 22, etc., may be different from features on the pressure side of the dovetail 18, such as a serration or tongue 22, etc. For example, the serration or tongue 22 on the suction side of the dovetail 18 may be shaped or arranged differently relative to the serration or tongue 22 on the pressure side of the dovetail 18. In some examples, the pressure side of the dovetail 18 may include one or more features that are not present on the suction side of the dovetail 18. In these examples, due to the asymmetry of the suction side of the dovetail 18 and the pressure side of the dovetail 18, the configuration of the seating area 114 (including its features 118) can ensure that the dovetail 18 is assembled in the seating area 114 in only one orientation. That is, the seating area 114 (including the feature 118 thereof) may be configured to matingly receive the serrations or tabs 22 on only one of the suction and pressure sides of the dovetail 18 .

[0060] The handling portion 106 may have a wall 120. The wall 120 enables handling by an operator, interfacing with the fluid dispensing device 200 ( Fig. 6A ) is mated with, connected to, a mounting structure for jetting operations or other processing structures now known or developed hereinafter. For example, and not intended to limit these embodiments in any way, wall 120 can be generally cylindrical. Alternatively, wall 120 can be polygonal or any other configuration capable of processing.

[0061] The wall 120 may have holes or openings 128 (see Figure 4AIn some examples, the processing portion 106 can be substantially hollow. More specifically, the wall 120 can define an internal passage or chamber 122 ( Figure 5 and Figure 6; see also Figure 8B ). The chamber 122 may include a receiving member 124 ( Figure 5 ), the receiving member 124 is configured to receive and hold the accessory 126 ( Fig. 6A ), such as tubing, pipes, or other devices for transferring fluid from the fluid distribution device 200 to the processing portion 106 ( Fig. 6A ) in other conduits or devices in the receiving member 124. In some examples, the receiving member 124 can be threaded and can be configured to threadably receive the accessory 126. In other examples, the receiving member 124 and the accessory 126 can include, but are not limited to, bayonet connections, interference fits, snap rings, and other connections now known or developed below. In still other examples, the receiving member 124 and the accessory 126 can be adhesively secured, welded, or secured using other suitable means. Once the accessory 126 is coupled to the receiving member 124, the accessory 126 can extend from the receiving member 124 to outside the chamber 122.

[0062] The focus is now on Fig. 7A and Figure 7B , Fig. 7A and Figure 7B The cap or second portion 150 is shown in more detail. Similar to the retaining portion 104 of the first portion 102, the second portion 150 can have an outer section 152 and an inner section 154. During the media jetting process, the outer section 152 can be exposed to the media, while the inner section 154 can be isolated from the media.

[0063] The outer section 152 can be curved. In some examples, the outer section 152 can be generally semi-elliptical and can have a first end 156A and a second end 156B. In some examples, the outer section 152 can have a channel or recess 158 extending from the first end 156A to the second end 156B. When the first part 102 and the second part 150 are coupled to each other as discussed herein, the channel 158 in the outer section 152 of the second part 150 can be coplanar with the channel or recess 112 of the first part 102.

[0064] The inner section 154 of the second part 150 can have an outer portion 160 and a receiving or placement area 162. In some examples, the outer portion 160 can surround at least a portion of the placement area 162. The outer portion 160 can have a notch 164. In some examples, the notch 164 can have one or more curved portions, for example, the notch 164 can be generally U-shaped. In other examples, the notch 164 can take other symmetrical or asymmetrical shapes (for example, the notch can be spherical, cuboid, concave strips, etc.). As discussed above, the ridge 116 of the first part 102 can be configured to match the notch 164 of the second part 150. Therefore, the notch (e.g., notch 164) can be any suitable component configured to be associated with the ridge (e.g., ridge 116) (e.g., geometrically interlocked) to facilitate the sealing fixation of the first part 102 and the second part 150.

[0065] When the first and second portions 102, 150 are coupled to each other, the ridge 116 of the first portion 102 can be received within or otherwise locked (e.g., geometrically locked) with the notch 164 of the second portion 150. The opening or hole 163 can be disposed in the outer portion 160 such that the notch 164 is located between the opening 163 and the seating area 162.

[0066] The seating area 162, like the seating area 114 of the first portion 102, can be generally concave and can include one or more features or protruding members 166 (hereinafter referred to as "features 166"). As described above, the seating area 114 of the first portion 102 can be configured to receive the serrations or tongues 22 of the dovetail 18 such that one of the suction side and the pressure side of the dovetail 18 faces the seating area 114. The seating area 162 (including its features 166) can be configured to receive the serrations or tongues 22 of the dovetail 18 such that the other of the suction side and the pressure side of the dovetail 18 faces the seating area 162. The features 166 of the seating area 162 can correspond to or be configured to mate with the tongues or serrations 22 on that side of the dovetail 18.

[0067] As one example according to these embodiments, the seating region 114 (including the feature 118 thereof) can be configured to receive and retain the dovetail 18 such that the pressure side of the dovetail 18 faces the seating region 114. Thus, the seating region 162 including the feature 166 can be configured to receive and retain the dovetail 18 such that the suction side of the dovetail 18 faces the seating region 114. In this way, due to the asymmetry of the suction and pressure sides of the dovetail 18, the dovetail 18 can be seated and retained within the seating region 114 of the first portion 102 and the seating region 162 of the second portion 150 in only one orientation.

[0068] In some aspects of the present invention, the first portion 102 and the second portion 150 can be configured to hold the blade 10 so that only the target surface of the blade 10 is exposed when the first portion 102 and the second portion 150 are coupled to each other. Thus, during the media blasting process, only the target surface of the blade 10 can be blasted with media. Fig. 8A The first and second portions 102, 150 are shown coupled or otherwise associated with each other (the blade 10 (e.g., its dovetail 18) is not held between the first and second portions 102, 150). When the first portion 102 is coupled to the second portion 150, the curved ridge 116 (see Figure 4A ) can be received in the curved recess 164 of the second portion 150 (see Figure 7B ). In addition, the channel 158 in the outer section 152 of the second part 150 can be coplanar with the channel 112 of the first part 102. Suitably strong O-rings (not shown for ease of understanding) can be located within the channels 112 and 158 to lockingly secure the first part 102 to the second part 150. Alternatively, a zipper (e.g., a metal zipper), aircraft wire, rubber covered wire, etc. can be located within the channels 112, 158 and used to secure the first part 102 to the second part 150. The concave surfaces of the channels 112 and 158 can ensure that the O-ring, zipper, aircraft wire, or rubber covered wire (collectively referred to as a locking member) does not slip off the first part 102 or the second part 150 when the first part 102 is secured to the second part 150. In some examples, the zipper, aircraft wire, rubber covered wire, or other suitable wire can be passed through the openings 117, 128 ( Figure 4A ) and the opening 163 in the second portion 150 ( Figure 7B ) to prevent or reduce relative movement of the first portion 102 relative to the second portion 150 and ensure effective masking of non-target surfaces of the blade 10.

[0069] To retain the blade 10 in the masking system 100, the dovetail 18 of the blade 10 can be seated in the seating area 114 of the first portion 102 so that the feature 118 corresponds to or matches the dovetail serration or tab 22 at one of the suction side or pressure side of the dovetail 18. Then, the second portion or cap 150 can be coupled to the first portion 102. When so coupled, the feature 166 in the seating area 162 of the second portion 150 can correspond to or match the tab 22 on the other side of the dovetail 18. The dovetail 18 can be clamped in the seating areas 114, 162 so that only the target surface of the blade 10 is exposed and the non-target surface of the blade 10 is masked and protected from the media. The locking piece can be located in the channels 112, 158 to secure the first portion 102 and the second portion 150 so that the blade 10 is securely secured in the seating areas 114, 162. In some examples, a zipper or other suitable thread may be passed through the openings 117 , 128 , 163 to ensure that the first portion 102 and the second portion 150 are securely coupled to prevent the media from contacting non-target surfaces of the blade 10 .

[0070] In aspects of the present disclosure, the first part 102 and the second part 150 can be manufactured in an additive manner, respectively. In some examples, the first part 102 and the second part 150 can be manufactured using photopolymerization curing technology. Photopolymerization curing technology (such as photopolymerization rapid prototyping, direct light processing, continuous liquid interface production, solid grinding curing, etc.) is a type of additive manufacturing method that selectively cures materials (e.g., resins or other photopolymers) by targeted light-activated polymerization to produce three-dimensional objects. When exposed to certain wavelengths of light, liquid photopolymer molecules can be quickly combined together and cured into a solid state through a process called photopolymerization. The liquid photopolymer can be contained in a container or barrel, and the build platform is partially immersed near the surface of the liquid. Using information provided by a CAD or other design file, the printer can guide the light source to selectively cure the liquid photopolymer into a solid layer. Then, the build platform can then be re-immersed in the remaining resin, and the process can be repeated for the next layer until the first part 102 and / or the second part 150 has been completely printed.

[0071] In some aspects, the first portion 102 and the second portion 150 can be additively manufactured using an elastomeric material or other compliant material (collectively referred to as "elastomeric material") having a low Young's modulus (e.g., a Young's modulus of less than 10 gigapascals (GPa)). In some examples, the first portion 102 and the second portion 150 can be additively manufactured using a material having a high failure strength and / or a high grinding resistivity so as to withstand the impact of the media during the media jetting process without degradation. For example, the first portion 102 and the segment portion 150 can be additively manufactured using silicone, rubber, urethane, or other suitable materials. In some examples, different materials can be used to manufacture (e.g., additively manufacture) the first portion 102 and the second portion 150.

[0072] Compared to using conventional techniques (e.g., molding) to manufacture the masking system 100, using an elastomeric material to additively manufacture the masking system 100 can provide one or more benefits. Using an elastomeric material to additively manufacture the system 100 can ensure that the first portion 102 and the second portion 150 are sufficiently flexible and conform to the surface of the blade 10 that is retained in the masking system 100. In some examples, additively manufacturing the first portion 102 and the second portion 150 with an elastomeric material can ensure that the first portion 102 and the second portion 150 are sealed to each other when the dovetail 18 is retained therein, thereby ensuring that no media (e.g., gravel or sand) contacts the non-target surface of the blade 10. In addition, compared to other conventional methods, the additive manufacturing masking system 100 can ensure manufacturing repeatability and consistent masking lines. Relative to other conventional manufacturing processes, using additive manufacturing to manufacture complex components (such as the first portion 102 and the second portion 150, etc.) can also be more economically feasible.

[0073] In an example, the first portion 102 and the second portion 150 can be additively manufactured using a silicone elastomer having a Shore hardness in a range between about 50A and about 90A. IND402 can be used to additively manufacture the first portion 102 and the second portion 150. In other examples, an elastomeric three-dimensional printable polymer (e.g., a resin, pellet, filament, powder, and a printable polymer now known or developed below) that provides a minimum Shore hardness of about 76A and a minimum tear strength of about 28kN / m can be used to additively manufacture the first portion 102 and the second portion 150. Using an elastomer having a Shore hardness ranging between about 50A and about 90A and a minimum tear strength of about 28kN / m can ensure that the first portion 102 and the second portion 150 are appropriately flexible to conform to non-target surfaces and are still durable enough to withstand the impact of the media. The masking system 100 made using such an elastomer can have excellent wear resistance and can be reused multiple times to mask the blade 10 for media jetting operations.

[0074] Another benefit of using an elastomeric material to additively manufacture the masking system 100 may be that the first portion 102 and the second portion 150 may be secured to each other while the blade 10 is held therein without the need for screws, nuts and bolts, or other such fasteners that require tools for tightening (such as screwdrivers or pliers, etc.). Masking systems that require screws, nuts and bolts, or other such fasteners (collectively referred to as screws) have a high likelihood of being damaged if the screws are overtightened, and conversely, may not effectively mask non-target surfaces if the screws are not properly tightened. Due to its design and elastomeric construction, the tool-less masking system 100 may provide a compliant shield for selectively and effectively masking surfaces of the blade 10 for media jetting operations.

[0075] Another benefit of the masking system 100, as compared to conventional masking techniques and systems, may be that the masking system 100 may reduce or eliminate the possibility of media being embedded in the cooling holes 32 or other portions of the blade 10 during the media spraying process. As described above, the wall 120 of the treatment portion 106 may define a generally hollow chamber 122 that includes a receiving member 124. The chamber 122 may have an open lower end 140 (see Figure 5 ). On the opposite end, the chamber 122 may have an opening 142 that feeds into the seating area 114 (see Figure 4A ). In some examples, attachment 126 ( Fig. 6A ) can be connected (e.g., threadedly connected or connected via a quick connect or other device) to the receiving member 124 at one end 144 of the accessory 126.

[0076] In some examples, the opposite end 146 of the attachment 126 can be operably coupled to Fig. 6A14. The fluid dispensing device 200 is schematically shown in FIG. The fluid dispensing device 200 can be configured to dispense a fluid, such as air, water, mist, steam, or any fluid. In some examples, the fluid dispensing device 200 can be configured to dispense pressurized air or another gas. In some examples, the fluid dispensing device 200 can be an air compressor. The pressurized fluid can enter the accessory 126 from the fluid dispensing device 200 and exit the accessory 126 through the opening 142. In the case where the dovetail 18 is secured by the first portion 102 and the second portion 150, the pressurized fluid can exit through the opening 142, via the air inlet orifice 30 ( Figure 1 ) enters the blade 10 via the cooling holes 32. The fluid may thus create a positive pressure within the blade 10 and serve to create a protective film around the airfoil 12. During the media blasting process, when a media (e.g., sand or grit) is blasted onto the blade 10 using the media blasting device, the media may be prevented from becoming stuck in holes in the blade 10 (e.g., in the cooling holes 32) due to the pressurized fluid fed into the blade 10 by the fluid distribution device 200. For example, fluid distributed into the attachment 126 by the fluid distribution device 200 may enter the blade 10 via the air inlet orifices 30, and may exit the cooling holes 32 with sufficient positive pressure to prevent the media from becoming stuck in the cooling holes 32 during or after the media blasting process. In this manner, a target surface of the blade 10 may be repeatedly blasted with media without causing damage from the media, which may otherwise have become stuck within the blade 10. Figure 6B Illustrated is a media spray device 202 that sprays media onto a target surface of a blade 10 held within the mounting system 100 while a fluid distribution device 200 distributes pressurized fluid to prevent the media from becoming stuck in the blade.

[0077] In some embodiments, the attachment 126 may be additively manufactured. In some examples, the attachment 126 may replace all or a portion of the processing portion 106 (e.g., the attachment 126 may be additively manufactured and form the base of the retaining portion 104 for additive manufacturing of the first portion 102). The attachment 126 may be any attachment configured or operable to deliver pressurized fluid to the blade 10 (e.g., via the opening 142 in the retaining portion 104) to ensure that the media from the media jetting process does not get stuck in the cooling holes 32 or other openings of the blade 10.

[0078] Fig. 9 A masking system 300 is shown in another aspect of the present disclosure. The masking system 300 may be similar to the masking system 100 except as noted. Although with any noted deviations, corresponding parts may be indicated by corresponding reference numerals.

[0079] The masking system 100 discussed above may include a first portion 102 and a second portion 150 that together hold the blade 10 so that non-target surfaces of the blade 10 are masked and protected from the media during the media jetting process. As discussed, the first portion 102 includes a seating area 114 having a feature 118, and the second portion 150 includes a seating area 162 having a feature 166. The first portion 102 (e.g., the receiving member 124 in the processing portion 106 thereof) may allow the fluid distribution device 200 to be operably coupled to the masking system 100.

[0080] The masking system 300 may also include a first portion 302 (see Fig. 10A ) and a second portion 350 (see Fig. 10B ), the first portion 302 and the second portion 350 together hold the blade 10 so that the surface of the blade 10 (except its target surface) is masked and protected from the impact of the media during the media spraying process. Similar to the first portion 102, the first portion 302 may include a holding portion 304 and a processing portion 306. In addition, similar to the holding portion 104 and the second portion 150 of the first portion 102, the holding portion 304 and the second portion 350 of the first portion 302 may include a seating area 314, 362 having features 318, 366, respectively. The seating area 314, 362 can be configured to receive the blade 10, for example, the dovetail 18, in only one orientation. For example, as discussed above for the masking system 100, the suction side and the pressure side of the dovetail 18 can be asymmetric, and the seating area 314, 362 can be configured to receive only one of the suction side and the pressure side of the dovetail 18 in a paired manner. Similar to the first portion 102, the first portion 302 can have a processing portion 306. The handling portion 306 (e.g., the receiving member 324 thereof) can allow the fluid dispensing device 200 to be operably coupled to the masking system 300. For example, an attachment, such as the attachment 126, can be used to operably couple the fluid dispensing device 200 to the first portion 302. As described above with respect to the masking system 100, in some examples, the attachment 126 can be additively manufactured and can form a base for the retaining portion 304 of the first portion 302.

[0081] The differences between the masking system 100 and the masking system 300 may relate to the manner in which the first portion 302 and the second portion 352 are secured to each other to hold the blade 10. Specifically, the second portion 150 of the masking system 100 may include a seating area 162 and an outer portion 160 outside the seating area 162. The second portion 350 of the masking system 300 may also include a seating area 362 and an outer portion 360 outside the seating area 362. However, unlike the outer portion 160, the outer portion 360 of the second portion 350 may include one or more locking members extending generally horizontally from the outer portion 360. For example, as shown in FIG. Fig. 9 and Fig. 10B As shown, locking members 402, 404 extend from the outer portion 360 of the second portion 350. In some examples, the locking member 402 can extend from the outer portion 360 on one side of the receiving area 362, and the locking member 404 can extend from the outer portion 360 on the other side of the receiving area 362. In other examples, one or more locking members can extend from the receiving area 362 or can be arranged elsewhere on the second portion 350. In some examples, a single locking member or more than two locking members can be provided on the second portion 350. One or more of the locking members (e.g., locking members 402, 404) can be configured to secure or facilitate the securement of the second portion 350 to the first portion 302. For example, as discussed herein, the locking members 402, 404 can be geometrically interlocked with corresponding features in the first portion 302 (e.g., in the outer portion 313 thereof).

[0082] In some aspects of the present disclosure, and as Fig.11A As shown in , the locking member 402 may have a horizontal member 410 extending generally horizontally from the outer portion 360, a spherical member 412 extending from the horizontal member 410, and a vertical member 414 extending from the spherical member 412. In some examples, the locking member 404 may be generally the same as the locking member 402. Specifically, as shown in FIG. Fig. 11B As shown, the locking member 404 may have a horizontal member 420 extending generally horizontally from the outer portion 360 , a spherical member 422 extending from the horizontal member 420 , and a vertical member 424 extending from the spherical member 422 .

[0083] As discussed above, the masking system 100 can be additively manufactured using elastomeric materials. The masking system 300 can be additively manufactured using similar materials. The elastic construction of the masking system 300 includes additively manufactured locking members 402, 404, which can allow both locking members 402, 404 to be temporarily pulled away from the seating area 362 in opposite directions. For example, the locking member 402 can be moved in direction A ( Fig. 10B) can be pulled, and the locking member 404 can be pulled in the opposite direction B. Once the pulling force is removed, the locking members 402, 404 can elastically rebound or otherwise return to or toward their initial positions.

[0084] The first portion 102 of the masking system 100 may have a seating area 114 and an outer portion 113 partially surrounding the seating area 114. Similar to the first portion 102, the first portion 302 may also have a seating area 314 and an outer portion 313 partially surrounding the seating area 314. Unlike the outer portion 113, the outer portion 312 may have a concave portion 502 located on one side of the seating area 314 and a concave portion 504 located on the other side of the seating area 314 ( Fig. 10A , Fig.11A as well as Fig. 11B ). The recessed portion 502 can be configured to lockingly receive the locking member 402, and the recessed portion 504 can be configured to lockingly receive the locking member 404. For example, Fig.11A As shown, the concave portion 502 of the first portion 302 may include a curved portion 510 configured to receive the spherical member 412 of the locking member 402 of the second portion 350. Fig. 11B As shown, the concave portion 504 of the first part 302 may include a curved portion 512, which is configured to receive the spherical member 422 of the locking member 404 of the second part 350. When the first part 302 is connected to the second part 350 after the dovetail 18 is placed in the placement area 314, the locking members 402 and 404 can be pulled in directions A and B respectively; the locking members 402 and 404 can move toward their initial positions due to their elastic configuration and match (e.g., geometrically interlock) with the concave portions 502 and 504 respectively. In this way, the first part 302 and the second part 350 (the blade 10 is retained therein) can be fixed (e.g., sealed) to each other for masking operation. To unlock the system 300, the user can use the vertical members 414 and 424 to pull each locking member 402 and 404 away from the recessed portions 502 and 504 respectively. Thus, the locking members 402 , 404 may be separated from the recessed portions 502 , 504 , respectively, to separate the first portion 302 from the second portion 350 .

[0085] Although Fig. 10BSpecific configurations of the locking members 402, 404 are shown, but those skilled in the art will appreciate that this is exemplary only. The second portion 350 can have any locking member that can be used to secure the first portion 302 to the second portion 350. For example, the second portion 350 can have a spherical locking member, a pyramidal locking member, a snap ring, a hook, or any other symmetrical or asymmetrical locking member now known or subsequently developed that can be used to secure the first portion 302 and the second portion 350. In some embodiments, the locking members can be alternately or additionally disposed on the first portion 302. In some examples, the locking members 402, 404 on one of the first portion 302 and the second portion 350 can be configured to geometrically interlock with the other of the first portion 302 and the second portion 350.

[0086] Fig.12 6 is a flow chart illustrating a method 600 for manufacturing and using a masking system (such as masking system 100 and / or masking system 300, etc.) to perform a masking operation. At box 602, a first portion and a second portion may be additively manufactured using an elastomeric material. In some examples, the first portion may be additively manufactured separately from the second portion. At box 604, a blade 10 may be placed in a placement area of ​​the first portion. At box 606, the second portion may be fixed to the first portion so that the blade 10 is firmly held within the masking system and only its target surface is exposed. At box 608, a fluid distribution device is operably connected to the masking system. At box 610, a medium injection device may be used to inject a medium onto a target surface when the fluid distribution device distributes the fluid into the cooling passage of the blade.

[0087] Thus, as has been described, masking systems (eg, masking system 100 and masking system 300 ) may provide a compliant shield that protects non-target surfaces during a media blasting process and ensures that media does not become lodged in cooling holes of a blade.

[0088] Based on the disclosure herein, those skilled in the art will appreciate that grit blasting or sand blasting is only one media blasting technique and that aspects of the present disclosure may also be used with other media blasting techniques such as shot blasting, glass bead blasting, etc. Furthermore, while the present disclosure focuses on gas turbine components, such as blades and vanes thereof, those skilled in the art will appreciate that the techniques described herein may be used to hold and media blast other suitable components.

[0089] 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 deviate 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.

[0090] It will 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 masking system for masking a component used in a media jetting process, the masking system comprising: a first portion additively manufactured and having a retaining portion having a seating area, a handling portion, and a receiving member configured to operably receive a fluid dispensing device; as well as A second portion, the second portion being additively manufactured and having a second retaining portion including a second seating area, the second portion being configured to be fixed to the first portion such that the component is seated within the seating area and the second seating area, and at least a portion of the component is concealed by the first portion and the second portion.

2. The masking system according to claim 1, wherein: The first portion and the second portion are respectively manufactured using an elastomeric material in an additive manner.

3. The masking system of claim 1, wherein: The seating area and the second seating area are collectively configured to retain the component in only one component orientation.

4. The masking system of claim 1, wherein: The retaining portion includes an outer section having a channel.

5. The masking system of claim 4, wherein: The second retaining portion includes a second outer section having a second channel.

6. The masking system of claim 5, wherein: The channel and the second channel are coplanar when the first portion is secured to the second portion.

7. The masking system of claim 1, wherein: One of the first portion and the second portion includes a locking member.

8. The masking system of claim 7, wherein: The locking member is configured to be received within a recess of the other of the first and second portions including the one of the locking member.

9. The masking system of claim 1, wherein: The first portion includes a ridge, and the second portion includes a notch corresponding to the ridge.

10. The masking system of claim 1, wherein: The component is a blade of a gas turbine.

11. The masking system of claim 1, wherein: The media blasting process is a sandblasting process.

12. The masking system of claim 1, wherein: The receiving member is located within the processing portion.

13. An additive manufacturing masking system, the masking system being used to mask a blade for a media jetting process, the masking system comprising: a first portion and a second portion fixable to the first portion, the first portion and the second portion being configured to collectively hold the blade so that only a target surface of the blade is exposed; the first portion and the second portion being additively manufactured; Wherein the masking system is configured to operably receive a fluid dispensing device for dispensing a fluid during the media jetting process.

14. The additive manufacturing masking system of claim 13, wherein: The first part and the second part are respectively additively manufactured using an elastomeric material.

15. The additive manufacturing masking system of claim 13, wherein: The first portion is configured to be coupled to the second portion without the use of any tools.

16. A method of masking a component, comprising: obtaining an additively manufactured masking device, the masking device comprising a first portion and a second portion; operably coupling a fluid dispensing device to the masking device; securing the first portion to the second portion such that the component is held by the first portion and the second portion and only a target surface of the component is exposed; as well as The fluid dispensing device is operated to dispense fluid into the component.

17. The method according to claim 16, wherein: The first part and the second part are additively manufactured using photopolymerization curing technology.

18. The method according to claim 16, wherein: The first portion includes a chamber having a receiving member for operably receiving the fluid dispensing device.

19. The method according to claim 16, wherein: The first portion and the second portion each have a corresponding recessed portion configured to collectively retain the component.

20. The method of claim 16, further comprising media jetting the target surface while the fluid dispensing device dispenses fluid into the component.

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