Assembly for movably holding component and method for positioning component

Abstract

The invention provides an assembly for movably holding a component and a method for positioning a component relative to an electrode for an electrically driven plating process. The assembly includes a tool assembly and a device. The tool assembly includes a tool base and a carrier. The tool base includes a frame and a guide. The frame is configured to hold the component. A guide is associated with the multi-axis path. The carrier is movably coupled to the guide. The device is coupled to the carrier and is movable with the carrier along a multi-axis path.

Description

Technical Field

[0001] The present disclosure relates generally to the field of tools. More specifically, aspects of the present invention relate to tools for holding gas turbine components while a coating is applied to the component via an aqueous coating process. Background Art

[0002] The following presents an overview of the present invention in order 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 of the present disclosure, an assembly for movably holding a component is disclosed. The assembly includes a tool assembly and a device. The tool assembly includes a tool base and a carrier. The tool base includes a frame and a guide. The frame is configured to hold the component. The guide is associated with a multi-axis path. The carrier is movably coupled to the guide. The device is coupled to the carrier and can move along the multi-axis path with the carrier.

[0004] In one aspect, according to the preceding aspect, the multi-axis path is a helical path and the device is an electrode, wherein the device facilitates machining of a component.

[0005] In one aspect, according to any of the preceding aspects, the component is a bucket segment having a plurality of buckets; the apparatus comprises: an electrode having a plurality of plates; at least one of the plurality of plates being positionable adjacent to at least one of the plurality of buckets along a multi-axis path.

[0006] In one aspect, according to any of the preceding aspects, the carrier has a collar and a curved flange.

[0007] In one aspect, according to any of the preceding aspects, the collar is configured to extend around the guide.

[0008] In one aspect, according to any of the preceding aspects, the guide comprises a shaft and a helical key associated with the multi-axis path; and the carrier comprises a collar configured to extend around the guide and comprising a keyway to receive the helical key.

[0009] In one aspect, according to any of the preceding aspects, the frame comprises a stopper configured to limit movement of the carrier along the guide.

[0010] In one aspect, according to any of the preceding aspects, the component comprises at least one tab for supporting the component.

[0011] In one aspect, according to any of the preceding aspects, at least one tab is removably attached to the tool base.

[0012] In one aspect, according to any of the preceding aspects, the carrier comprises a clamp configured to be movably secured to the guide.

[0013] In one aspect, according to any of the preceding aspects, the device is an anode and when the assembly is used for electroplating of a component, the component forms at least part of a cathode.

[0014] In one aspect of the present disclosure, an assembly for movably holding a component is disclosed. The assembly includes a tool assembly and an electrode. The tool assembly includes a tool base and a carrier. The tool base includes a guide. The tool base is configured to hold the component. The guide includes a shaft and a spiral key associated with a spiral path. The carrier is movably coupled to the guide. The collar includes a collar configured to extend around the guide. The collar includes a keyway to receive the spiral key. The electrode is coupled to the carrier and is movable along the spiral path with the carrier.

[0015] In one aspect, according to the preceding aspect, the component is a bucket segment having a plurality of buckets; the electrode has a plurality of plates; at least one of the plurality of plates is positionable along a helical path adjacent at least one of the plurality of blades.

[0016] In one aspect, according to any of the preceding aspects, the carrier has a curved flange.

[0017] In one aspect, according to any of the preceding aspects, the tool base comprises a stop configured to limit sliding movement of the carrier along the guide.

[0018] In one aspect, according to any of the preceding aspects, the component comprises at least one tab for supporting the component.

[0019] In one aspect, according to any of the preceding aspects, at least one tab is removably attached to the tool base.

[0020] In one aspect, according to any of the preceding aspects, when the assembly is used to electroplate a component, the electrode is an anode and the component forms at least part of a cathode.

[0021] In one aspect of the present disclosure, a method of positioning a component relative to an electrode for an electrically driven plating process is disclosed. The method includes: holding the component with a tool base; coupling a carrier to a guide of the tool base, the guide associated with a multi-axis path; coupling an electrode to the carrier; and moving the carrier and the electrode relative to the component along the multi-axis path to position the electrode near the component.

[0022] In one aspect, according to the previous aspect, the component is a bucket segment having a plurality of buckets, and the electrode has a plurality of plates. The plurality of plates are moved along a multi-axis path relative to the plurality of buckets to position at least one of the plurality of plates adjacent to at least one of the plurality of buckets.

[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 It is a three-dimensional view of the turbine blades;

[0027] FIG. 3A to FIG. 3C is a view of a bucket section including a plurality of turbine buckets, an inner shroud segment, and an outer shroud segment;

[0028] Figure 4A is a perspective view of a coating assembly and a bucket segment supported on the coating assembly for an electrically driven coating process, showing a tool assembly and an anode of the coating assembly, wherein a carrier of the tool assembly and the anode are in a retracted position and axially spaced from the turbine bucket;

[0029] Figure 4B is similar to Figure 4A a perspective view of a coating assembly and bucket segment of FIG. 1 , but with the carrier and anode in an extended position so that the anode plate is inserted into a channel between adjacent pairs of turbine buckets;

[0030] Figure 5A is a top view of the coating assembly and bucket section showing the carrier and anode in a retracted position;

[0031] Figure 5B is similar to Figure 5A A top view of the coating assembly and bucket segment of FIG. 1 , but with the carrier and anode in an extended position;

[0032] Fig. 6A yes Figure 4A-Figure 5B A partial schematic diagram of an anode and bucket segment of FIG. 1 , showing the anode and bucket segment in a retracted position;

[0033] Figure 6B is similar to Fig. 6AA partial schematic diagram of a coating assembly and a bucket segment of FIG. 1 , but with the anode and bucket segment in an extended position;

[0034] Figure 7 and Figure 8 yes Figure 4A-Figure 5B a perspective view of a coating assembly of FIG. 1 , wherein the coating assembly is exploded to depict a tool base, a carrier, and an anode of the tool assembly;

[0035] Fig. 9 and Fig.10 yes Figure 4A-Figure 8 A front view of an anode;

[0036] Figure 11-13 yes Figure 4A-Figure 5B , Figure 7 as well as Figure 8 A view of a carrier of

[0037] Figure 14-17 yes Figures 4A-5B , Figure 7 as well as Figure 8 a view of a tool base; and

[0038] Fig.18 It shows that in use FIG. 4A to FIG. 5B A flow chart of a method for plating components during an electrically driven plating process of a plating component. DETAILED DESCRIPTION

[0039] 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 as the air passes through the rear stage of the compressor, its temperature and pressure increase. 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 a turbine, causing the turbine to rotate, thereby driving the compressor. The output of the gas turbine engine can be mechanical thrust via the 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.

[0040] 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 in order 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.

[0041] Figure 1A 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. The bottom wall 25 may be part of a metering plate 35 that is brazed or otherwise secured to the dovetail 18.

[0042] The airfoil 12 may have a pressure side 26, a suction side 27 opposite to the pressure side 26, a tip 28, a leading edge 29, and a trailing edge 31. The tip 28 may include or may be configured to interact with a shroud. The shroud may be provided at the tip 28 of each blade 10 or may be a stationary ring comprising one or more circumferentially extending sections, one or more circumferentially extending sections being connected to the gas turbine casing, respectively. The shroud may be configured to seal the gap between the tip 28 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 combustion gases at extremely high temperatures. The airfoil 12 or a portion thereof may therefore be coated with heat-resistant, wear-resistant, corrosion-resistant, and / or other coatings.

[0043] 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 tip 28, the leading edge 29, the trailing edge 31, 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.

[0044] Gas turbine blades, such as blade 10, can be manufactured using investment casting, also known in the art as lost wax machining. The investment casting process can involve making an accurate negative mold of the blade shape, which is filled with wax to form the blade shape. If the blade, such as blade 10, is hollow and has internal cooling channels, a ceramic core in the shape of the cooling channels can be inserted in the middle. The wax blade can be coated with a heat resistant material to make a shell, which can then be filled with the blade alloy.

[0045] Once cast, the blade 10 may undergo one or more trimming processes to prepare the blade 10 for operation. The trimming process may ensure that the blade 10 has a desired aerodynamic profile, as this may affect engine efficiency and fuel consumption. The trimming process may also make the blade 10 more fatigue-resistant and thereby increase the life of the blade 10. Some trimming processes may reduce maintenance requirements associated with the blade 10.

[0046] Trimming the blade 10 may include coating one or more surfaces of the blade 10. For example, one or more surfaces of the blade 10 may be blasted with abrasive media to configure the surfaces to receive a plating or other type of coating (the plating or other coating may be a heat resistant coating, a wear resistant coating, and / or other coating applied to one or more surfaces of the blade 10). Trimming the blade 10 may also include deburring and breaking sharp edges, polishing one or more surfaces of the blade 10 to remove excess material, welding, brazing, or otherwise associating features (e.g., the metering plate 35) with the blade 10, machining one or more surfaces of the blade 10, and the like.

[0047] The blade 10 may also undergo one or more coating processes, such as an electrically driven coating process, etc. The blade 10 may be plated or otherwise coated with a heat-resistant coating, a wear-resistant coating, a corrosion-resistant coating, and / or other coatings. Electrically driven coating processes (i.e., electroplating (or electrodeposition)) are used in the aviation industry to coat various components. As described below, electroplating may be used to coat the surface of a component with a metal layer by electrolysis. The electroplating process may include a device in the form of an electrode, and the electrode promotes the coating of the component via electrolysis. For example, the electroplating process may utilize an anode (the anode acts as a positively charged electrode) and a cathode (the cathode acts as a negatively charged electrode). The component to be plated may form at least a portion of the cathode, and the component may be immersed in an electrolyte together with the anode. When an electric current passes through the system, the anode releases positive metal ions into the electrolyte solution. These metal ions dissolve in the solution and may then be deposited on the surface of the component.

[0048] The cathode component acts as a deposition site where metal ions are deposited onto the surface of the component. In at least some examples, the metal can be deposited on the component to produce a uniform and adherent metal coating. Aerospace components, such as blades and vanes, can be coated using electrically driven waterborne methods to achieve desired electrical and corrosion resistance, reduce wear and friction, increase heat resistance, and the like.

[0049] In some examples, an electroplating process may be used to coat one or more portions of the blade 10. The electroplating process for coating the blade 10 (or other component) may employ a cathode and an anode. A component such as an aerospace component (e.g., blade 10) or other component may provide at least a portion of a cathode to achieve coating via an electroplating process.

[0050] The anode may be located adjacent to the cathode (e.g., blade 10) to produce a uniform metal coating. Among other factors, consistent spacing between the anode and the cathode (e.g., blade 10) may be necessary to produce a uniform coating. In at least some embodiments, placement of the anode adjacent to the blade 10 may involve a manual process in which the anode is manually formed and oriented to achieve the desired spacing between the anode and the cathode (e.g., blade 10).

[0051] One problem associated with manual anode placement is that such a process can be labor intensive and time consuming. In addition, consistent spacing between the anode and cathode (e.g., blade 10) is often challenging to achieve using manual anode placement. Skilled labor may be required to meet coating quality and consistency requirements. If it is determined that the coating has an inconsistent thickness (or if the coating includes any other defects), the blade 10 may need to be reworked to correct any problems with the coating. Because rework can be time consuming and expensive, efficiencies can be gained by minimizing the need for rework.

[0052] A mechanism (not shown) can be used to selectively lower the cathode and anode into a tank (not shown) so as to be suspended in the plating solution. In some examples, the component is at least partially immersed in a "P-salt" platinum solution during the electroplating process. In other examples, alternative electroplating solutions can be used to apply one or more layers of plating to the at least partially immersed component.

[0053] In at least some non-limiting aspects of the present disclosure, the blade 10 may have a coating applied thereto that is not a plating and is not applied via electrolysis. Examples of such coatings may include heat resistant coatings, wear resistant coatings, corrosion resistant coatings, and / or other coatings.

[0054] For coatings that can be applied to the blade 10 without the use of electrolysis, it will be understood that the blade 10 may not be immersed in the electroplating solution. In addition, instead of using an anode to facilitate the application of the coating, the coating may be sprayed, poured, spread or otherwise applied to the blade 10 using a device such as a nozzle or other mechanical device.

[0055] Steering Figure 2 , another gas turbine component includes a gas turbine bucket 40 according to an aspect of the present disclosure. The turbine bucket 40 generally includes an airfoil 42 extending between a top or gas path inner surface 44 of an inner shroud segment 46 and a bottom or gas path outer surface 48 of an outer shroud segment 50. The turbine bucket 40 also includes a root dovetail 52 depending from a lower surface 54 of the inner shroud segment 46. The dovetail 52 may include one or more serrated protrusions or tongues 56 extending laterally from one side of the dovetail 52 to an opposite side of the dovetail 52. The dovetail 52 may terminate at an end or bottom wall 58 that may span between dovetail sides 100. The dovetail 52 (including the tongue 56 and its bottom wall 58) may be adapted to interlock in a corresponding slot defined in a casing of the gas turbine engine.

[0056] The airfoil 42 may have a pressure side 60, a suction side 62 opposite the pressure side 60, a tip 64, a leading edge 66, and a trailing edge 68. The tip 64 may include an outer shroud segment 50. The inner shroud segment 46 and the outer shroud segment 50 may extend circumferentially and include a plurality of portions of corresponding retaining rings that are connected to the gas turbine casing. The airfoil 42 (e.g., its pressure side 60) may be in contact with combustion gases at extremely high temperatures. The airfoil 42 or portions thereof may therefore be plated or otherwise coated with heat-resistant coatings, wear-resistant coatings, corrosion-resistant coatings, and / or other coatings. Similar to the blade 10, the turbine blade 40 may be electroplated and may form at least a portion of a cathode for an electroplating process.

[0057] The coating process associated with turbine bucket 40 may utilize manual anode placement techniques similar to those used for blade 10. Furthermore, the drawbacks associated with manual anode placement (noted above for blade 10) may apply to manual techniques for placing anodes relative to turbine bucket 40.

[0058] Figure 3A-3C A shroud bucket segment or cluster 100 (hereinafter "bucket segment 100") according to some aspects of the present disclosure is shown. The bucket segment 100 includes a plurality of buckets 102, an inner shroud segment 104, and an outer shroud segment 106. The inner shroud segment 104 and the outer shroud segment 106 have a gas path inner surface 108 and a gas path outer surface 110, respectively.

[0059] See Figure 4- Fig.17 In certain aspects of the embodiments, the buckets 102 may be attached to and cooperatively supported by the shroud segments 104, 106. The bucket segment 100 may include a plurality of pairs of adjacent buckets 102, each pair of buckets having a passage 111 extending therebetween (see FIG. Fig. 6A In particular, each pair of adjacent vanes 102 has a plurality of gas path inner surfaces 108 and 110 that are opposed to each other and cooperate with the gas path inner surface 108 and the gas path outer surface 110 to define a corresponding passage 111 (see Figure 3A and Fig. 6A ) of the pressure surface 102a and the suction surface 102b (see Fig. 6A and Figure 6B ).

[0060] Similar to the blades 10 and the turbine buckets 40, the bucket segments 100 may be plated via an electroplating process. The plating process for the bucket segments 100 may also utilize the manual anode placement techniques described above. Specifically, a series of anodes (not shown) may be formed and each anode may be manually oriented adjacent to a corresponding bucket 102 of the bucket segment 100. Manual placement of an anode relative to each turbine bucket 102 of the bucket segment 100 may be laborious and time consuming. Furthermore, achieving accurate and consistent anode positioning relative to each bucket 102 associated with the bucket segment 100 may be challenging.

[0061] The fixed arrangement of the buckets 102 in the bucket section 100 may further exacerbate the challenges associated with manual anode placement. For example, the proximity of adjacent buckets 102 may limit access to at least some pressure and suction surfaces of the buckets 102. Specifically, because each bucket 102 in the bucket section 100 may be immediately adjacent to one or more adjacent buckets 102, it may be difficult for a technician to accurately position an anode element between a pair of adjacent buckets 102. Inconsistent positioning between the anode element and the bucket 102 may result in a plating on the bucket 102 having an inconsistent thickness and, thus, requiring the bucket 102 to be re-plated and / or otherwise repaired.

[0062] Furthermore, the blades 102 of the blade section 100 may be angled relative to the turbine axis X' (see Fig. 6A In this angled blade configuration, the chord C of the bucket 102 may be angled relative to the turbine axis X' to define an airfoil pitch angle P (see Fig. 6A If the anode component is inserted between the buckets 102 in a vertical direction (e.g., along the axis X'), the anode component may contact the buckets 102 and undesirably damage the anode component and / or the buckets 102. Therefore, it may be desirable to insert the anode component along an insertion direction that is oblique to the turbine axis X' (e.g., an insertion direction that is substantially parallel to the chord C) because this ensures that the anode component does not contact the buckets 102 and damage the anode component and / or the buckets 102.

[0063] Steering Figures 4A-6BAccording to aspects of the present disclosure, assembly 112 is operable to facilitate processing (e.g., plating, coating, machining, etc.) of a component (e.g., an aerospace component or other component, etc.). In some examples, assembly 112 may movably hold a component for processing. In some examples, assembly 112 is operable to facilitate plating of a component (e.g., a bucket segment 100, etc.) during an electrically driven plating process. Assembly 112 may be configured to support and hold a component and may include an anode 114 adjacent to the component during the plating process. In some examples of embodiments, assembly 112 may include anode 114 and tool assembly 115. As will be explained, tool assembly 115 may facilitate precise relative movement between the component and anode 114.

[0064] Anode 114 may be of unitary or non-unitary construction and may include a series of mesh anode plates 116 attached to and supported by anode stems 118 (see Figure 4A , Fig. 9 as well as Fig.10 ). The anode stem 118 may have an arcuate shape that conforms to the curved shape of the bucket segment 100. More specifically, the anode stem 118 may have a radially outer surface 120 (see Fig.10 ), the radially outer surface 120 is operable to be adjacent to the gas path outer surface 108 ( Figure 3A ) positioning. The anode stem 118 may have a radially inner groove 122 with a series of vertical grooves 123 (see Fig. 9 ). The slot 123 can be configured to receive the tool assembly 115 and index with the tool assembly 115. In other examples, the anode rod 118 can be configured interchangeably (e.g., for appropriate plating of adjacent components). For example, other examples of the anode rod 118 can have a substantially linear shape (such that the anode rod 118 is not curved). In yet other examples, the anode rod 118 can include a plurality of discrete segments that are removably attached to each other. In at least some non-limiting aspects of the embodiments, the anode 114 can include various anode types, such as a conformal grid type, a non-conformal grid type, a rod type, a conformal plate type, a non-conformal plate type, and / or a point type, etc.

[0065] At least one of the anode plates 116 may have opposing plate surfaces 124, 124' and a generally uniform pattern of holes 125 extending from one plate surface 124 to the other plate surface 124' (see Fig. 9). The anode plate 116 can be shaped such that the plate surfaces 124, 124' are curved (i.e., the surfaces are not planar). In various aspects, one or more anode plates 116 can have alternative configurations (e.g., for appropriate plating of an adjacent component or another component). In at least some non-limiting aspects of the embodiments, the anode plate 116 can have alternative arrays of holes 125 or alternative plate surface shapes. In some examples, one or more anode elements can have structures other than a plate shape, such as generally spherical, pyramidal, or other shapes.

[0066] Each anode plate 116 may have a plate axis X1 (see Fig. 6A ). The plate axis X1 and the guide axis X2 of the tool assembly 115 can cooperatively define the plate angle A1. The anode plates 116 can be arranged in series along the length of the anode rod 118 and can be extended from the lower edge 126 of the anode rod 118 (see Fig. 9 and Fig.10 ) protrudes axially. The anode plates 116 may be spaced apart from each other and spaced circumferentially around the guide axis X2 (see Figure 5A and Figure 5B As will be explained, one or more anode plates 116 may each be positioned adjacent to a pair of buckets 102 of a bucket section 100 and at least partially removably inserted therebetween.

[0067] In aspects of the present disclosure, at least a portion of the anode 114, such as the anode plate 116, etc., may include a titanium material to facilitate effective plating of one or more components. However, in other examples, the component 112 may have one or more anode elements that include alternative anode materials such as stainless steel. At least a portion of the anode 114 may be manufactured via a printing process such as laser bed powder fusion, a binder jetting process, or other suitable manufacturing processes.

[0068] According to one aspect of the present disclosure, tool assembly 115 may be operable to support and hold bucket segment 100 and anode 114 adjacent bucket segment 100 during a coating process. Tool assembly 115 may facilitate insertion and removal of anode 114 relative to bucket segment 100 without contacting or damaging anode 114 and / or bucket segment 100.

[0069] refer to FIG. 4A to FIG. 4B , Figure 7 , Figure 8 , Fig.11 as well as Fig.17 The tool assembly 115 may include a tool base 130 and a movable carrier 132 (see Figure 4A and Figure 4B). The tool base 130 may include a frame 134 and an arm 136. The frame 134 may be used to support the displaceable carrier 132, the bucket segment 100, and the anode 114. The arm 136 may be attached to the frame 134 for mounting the tool base 130 to a mechanism (not shown) that selectively lowers the bucket segment 100, the tool assembly 115, and the anode 114 into a tank (not shown) for suspension within the plating solution. Insertion of the anode 114 relative to the bucket segment 100 may occur prior to immersing the anode 114 and the bucket segment 100 in the plating solution.

[0070] The tool base 130 may also include bosses 138, 140 associated with the frame 134 for mounting and retaining the bucket segment 100 relative to the tool base 130 (see FIG. Fig.17 The tool base 130 may further include a stopper 141 (see Figure 4A and Fig.17 ), the stopper 141 is configured to limit the movement (eg, sliding) of the carrier 132 along the guide axis X2.

[0071] In use, the bucket segment 100 may be removably secured to the tool base 130 prior to coating of the bucket segment 100. The bucket segment 100 may be removably secured to the tool base 130 by attaching the tabs 104a, 106a (see FIG. 1 ) of the shroud segments 104, 106 to the tool base 130 using suitable fasteners (not shown). Figure 3A-3C ) are removably attached to corresponding bosses 138, 140 (see Fig.17 ) to secure. Thus, the tabs 104a, 106a may support the bucket segment 100 relative to the tool base 130.

[0072] The tool base 130 may further include a guide member 142 (see FIG. 1 ) that movably supports the carrier 132 and the anode 114. Figure 4A and Figure 4B That is, the carrier 132 may be movably coupled to the guide member 142. The guide member 142 may include an elongated shaft 144 and a guide element or a screw key 146 (hereinafter referred to as "guide element 146") formed integrally with each other (see Figure 4A , Fig.14 as well as Fig.17 In some examples, the shaft 144 and the guide element 146 (see Figure 4A ) also defines the guide axis X2 ( Fig.14 and Fig.15 ) and extends along the guide axis. The guide element 146 may have a spiral shape (ie, a spiral shape, see Figure 4B), wherein at least a portion of the guide element 146 extends along a multi-axis path (e.g., a spiral path) and defines the multi-axis path. The guide element 146 can have a dovetail profile shape that is substantially constant along the length of the guide element 146. In some aspects of the present disclosure, the guide element 146 can include a spiral key having an angled guide surface 150 (see Figure 4B and Fig.17 ), the guide surfaces 150 taper toward each other in a radially inward direction toward the shaft 144. As will be discussed, the guide element 146 can be engaged with a complementary spiral keyway 160 ( Figure 7 ) are slidably engaged so that when the carrier 132 moves axially along the guide 142, the guide 142 and the carrier 132 cooperate to provide a multi-axis drive 152 ( Figure 4A , Figure 4B , Figure 5A as well as Figure 5B ).

[0073] In at least some non-limiting aspects of the embodiments, the guide 142 can have one or more alternatively configured guide elements 146. For example, the alternative guide element 146 can have any of a variety of alternative contour shapes (such as an arcuate shape, a rectangular shape, or another polygonal shape, etc., which are not shown for ease of description).

[0074] Other alternative guide elements 146 are still within the scope of at least some aspects of the present disclosure. In some examples, the guide element 146 of the guide member 142 may include a groove or keyway that is operable to receive a key or other protrusion associated with the carrier 132. In still other examples, the multi-axis drive 152 may not have a spiral guide structure. For example, the alternative guide element 146 may define a non-spiral multi-axis path (such as a "zigzag" path or other non-spiral curved path).

[0075] The tool assembly 115 may include a chemically resistant polymer suitable for exposure to a plating process. For example, an acceptable chemically resistant polymer suitable for exposure to a plating process is a polypropylene material. The tool assembly 115 also includes a replaceable synthetic resin material, such as another polymer material, etc., especially a chemically resistant polymer suitable for exposure to a plating process is also within the scope of the present disclosure.

[0076] The movable support 132 can be used to movably support the anode 114 relative to the tool base 130, while the tool base 130 supports the bucket segment 100. The support 132 can be moved along the guide axis X2 in a retracted position (see Figure 4A ) and extended position (see Figure 4B) between the blade section 100 and the support member 132. In the retracted position, the support member 132 is axially spaced from the blade section 100, and in the extended position, the support member 132 is positioned adjacent to the blade section 100. The support member 132 broadly includes a guide element or fixture 154 (hereinafter "guide element 154", see Figure 4A-Figure 5B and Figure 11-13 ). The guide member 142 may be movably engaged with the guide element 154 and may allow the carrier 132 to move axially along the guide member 142.

[0077] The guide member 154 may include a pair of opposing clamp walls 156 (see Figure 4A and Fig.11 ), the pair of opposing clamp walls 156 extend around the shaft 144 and the guide element 146. The guide element 154 may include a guide member 142 (see Figure 4A and Figure 4B ) extends through a collar or carrier member 158 (hereinafter referred to as "collar 158", see Figure 7 ). The collar 158 may be interconnected with and integrally formed with the fixture wall 156. The collar 158 may include a helical keyway 160 having a dovetail profile shape that is substantially constant along the length of the guide element 154 (see Figure 7 and Figure 8 ). In particular, the helical keyway 160 (see Fig.11 ) can have angled guide surfaces 162 that taper toward each other in a radially inward direction toward the shaft 144.

[0078] Guide element 146 (see Figure 4A ) and spiral keyway 160 (see Figure 8 ) may be complementarily shaped and slidably engage one another so that the guide 142 and the carrier 132 cooperatively provide a multi-axis drive 152. When the carrier 132 moves axially along the guide 142, the multi-axis drive 152 may generate off-axis relative movement between the bucket segment 100 and the anode 114.

[0079] In use, the guide element 146 and the spiral keyway 160 can have corresponding spiral elements (such as the guide element 146 and the guide element 154, etc.) that are complementarily shaped and slidably engage each other to move the displaceable carrier 132 around the guide device 142 when the displaceable carrier 132 moves axially along the guide device 142. For example, the movable carrier 132 can slide axially along the guide member 142 while also rotating around the guide member 142. The guide element 146 defines a pitch angle A2 relative to the guide axis X2 (see Fig.14). The pitch angle A2 may be configured to facilitate passage through a passage 111 defined between a pair of corresponding blades 102 (see Fig. 6A ) of the spiral anode motion. The plate angle A1 ( Fig. 6A ) and spacing angle A2( Fig.14 ) can each be an inclination angle.

[0080] In at least some non-limiting aspects of embodiments, the carrier 132 can have one or more alternatively configured guide elements 154. For example, the alternative helical guide element 154 can have any of a variety of alternative profile shapes, such as an arcuate shape, a rectangular shape, or another polygonal shape.

[0081] Other alternative carrier guide elements 154 are still within the scope of at least some aspects of the present disclosure. In various aspects, the guide element 154 of the carrier 132 can include a key or other protrusion that is operably received by a keyway or other recess associated with the tool base.

[0082] In some examples, the multi-axis drive 152 may be free of a helical guide structure. For example, aspects of the multi-axis drive 152 may include one or more transmission (drive) elements (such as connecting rods, cams, gears, worms, sprockets, chains, pulleys, belts, etc.) for providing relative axial and off-axis motion between the anode element and the cathode element. It will also be understood that the drive 152 may include a motor (e.g., an electric motor, a hydraulic motor, or a pneumatic motor) for driving the anode and cathode (e.g., the component to be plated) relative to each other.

[0083] The carrier 132 may include a curved flange 164 ( Figure 11-13 ), teeth 166 and from the guide member 142 (see Figure 4A ) radially extending ribs 168 extending radially outward to the curved flange 164. The carrier 132 can extend radially outward relative to the guide 142 and can rotate about the guide 142. The carrier 132 can provide a cantilevered structure that enables the carrier 132 to support the anode 114 relative to the guide 142 and the bucket segment 100 while facilitating precise rotation and axial movement of the anode 114 relative to the bucket segment 100. Thus, the anode 114 (or another device that facilitates machining of the bucket segment 100 or another component) can be coupled to the carrier 132 and can move along a multi-axis path (e.g., along a spiral path) with the carrier 132.

[0084] At least a portion of the carrier 132 can be formed from a chemically resistant polymer suitable for exposure to a plating process. As embodied in the present disclosure, examples of suitable chemically resistant polymers suitable for exposure to a plating process include polypropylene materials. In some aspects of the present disclosure, the carrier 132 can be formed entirely of polypropylene. The process for forming the carrier 132 can include a stereolithography process, an adhesive jetting process, or other suitable manufacturing process. It is also within the scope of the present disclosure for the carrier 132 to include an alternative synthetic resin material, such as another polymer material, and in particular, a chemically resistant polymer suitable for exposure to a plating process.

[0085] As described above, the groove 122 and the groove 123 ( Fig. 9 ) can be configured to receive and align with the carrier 132 ( Figure 4A Specifically, the teeth 166 ( Fig.12 ) can be removably received in corresponding slots 123 to align anode 114 relative to carrier 132. Anode 114 and carrier 132 can be removably secured to each other by one or more fasteners (not shown for ease of illustration).

[0086] Thus, the anode 114 may be coupled to and supported by the carrier 132, while the bucket segment 100 is attached to and held by the tool base 130. However, in other examples, the anode 114 may be directly attached to the tool base 130, while the bucket segment 100 is attached to the carrier 132. In these examples, the bucket segment 100 may be movable along the guide 142 with the carrier 132.

[0087] As described above, during operation of the tool assembly 115, the anode plates 116 can be respectively positioned adjacent to a pair of buckets 102 of the bucket segment 100 and at least partially removably inserted between the pair of blades 102. With the anode 114 and the carrier 132 attached to each other, the anode 114 and the carrier 132 can be moved together and selectively positioned at a position along the guide 142. For example, when the carrier 132 is in the retracted position (see Figure 4A , Figure 5A 6A), the anode 114 may be axially spaced from the bucket 102. Alternatively, when the carrier 132 is in the extended position (see Figure 4B , Figure 5B as well as Figure 6B ), the plate 116 of the anode 114 can be inserted relative to the bucket segment 100 so that the anode plate 116 is at least partially removably inserted between multiple pairs of buckets 102 in the bucket segment 100.

[0088] Anode 114 and carrier 132 may be selectively positioned in a retracted position (see Figure 4A ) and extended position (see Figure 4B ) for removably inserting the anode 114 relative to the blade segment 100. In order to insert the anode 114 relative to the blade segment 100, the carrier 132 can be moved along the insertion direction (the insertion direction extends along the guide axis X2, see Fig. 6A ) from the retracted position to the extended position so that the anode plate 116 is at least partially inserted into the channel 111. In the extended position, the stopper 141 can engage the carrier 132 (see Figure 4B ) to limit further insertion of the anode plate 116 by limiting further sliding of the carrier 132 in the insertion direction along the guide 142. To remove the anode 114 from the bucket segment 100, the carrier 132 may be advanced in a direction opposite to the insertion direction (i.e., in a direction away from the bucket segment 100).

[0089] When the anode 114 is inserted relative to the bucket segment 100, the plate 116 may be at least partially located within the channel 111 defined between each pair of buckets 102. In addition, the anode stem 118 may be positioned adjacent to the gas path surfaces 108, 110. Thus, during the electroplating process, the anode stem 118 may promote plating of at least a portion of the surface 110, while the anode plate 116 may promote plating of at least a portion of the pressure surface 102a and the suction surface 102b of the bucket 102.

[0090] The anode plate has a plate axis X1, which can be substantially aligned with a channel axis X3 defined by the channel 111 (see Fig. 6A and Figure 6B ). A spiral element (such as guide element 146 and guide element 154) may facilitate spiral anode movement of the anode plate along the channel axis X3.

[0091] In other examples, one or more elements other than portions of the anode may be removably inserted between components of the alternative cathode. For example, one or more alternative airfoil components (such as blades, vanes, other airfoil elements, etc.) or other non-airfoil components may be plated or otherwise treated (e.g., by coating).

[0092] Fig.18A flow chart illustrating a method 200 of coating a component, such as a bucket segment 100, during an electrically driven coating process is shown. At step 202, an anode 114 may be coupled to and supported by at least one of a tool base 130 and a carrier 132. At step 204, a component may be attached to and held by at least another of the tool base 130 and the carrier 132. At step 206, the carrier 132 may be coupled to a guide 142 of the tool base 130. At step 208, the anode 114 may be displaced relative to the component along a spiral path into at least a partial intercalation between respective elements of the component. In some examples, step 208 may include the step of moving a plurality of anode elements along a spiral path into at least a partial intercalation between respective pairs of component elements. In some examples, step 208 may include the step of moving the anode 114 and the carrier 132 from a retracted position to an extended position for removably inserting the anode 114 relative to the bucket segment 100.

[0093] At step 210 , an electroplating process may be performed to plate at least a portion of the component.

[0094] Electroplating during step 210 may be used to coat the surface of the bucket segment 100 with a thin metal layer. The plating process may utilize an anode 114 and a bucket segment 100, with the anode 114 acting as a positively charged electrode and the bucket segment 100 acting as a cathode. Components (such as the bucket segment 100, etc.) may be at least partially immersed in a "P-salt" platinum solution during the electroplating process. In other examples, alternative electroplating solutions may be used to apply one or more coatings other than platinum to the at least partially immersed component. When current is passed through the system, the anode 114 releases positive metal ions into the P-salt solution. These metal ions dissolve in the solution and then deposit onto the surface of the component. After step 210, the component may be removed from the assembly 112.

[0095] During the electroplating process, the anode rod 118 can be used to plate at least a portion of the surface 110, and the anode plate 116 can be used to plate at least a portion of the pressure surface 102a and the suction surface 102b of the bucket 102. For example, platinum can be deposited on the bucket segment 100 to produce a uniform and adherent platinum coating. The anode 114 can be located near the bucket segment 100 to produce a uniform metal coating. Among other factors, a consistent spacing between the anode 114 and the bucket segment 100 can be developed to produce a uniform coating on the bucket segment 100. In yet other examples, one or more coatings other than plating can be applied to the component by an electrically driven coating process.

[0096] In at least some non-limiting aspects of the present disclosure, assembly 112 may be used to facilitate processing of a component via a process other than electroplating. For example, assembly 112 may facilitate coating of bucket segment 100 or another component via a nozzle or other device. Such coatings may include heat resistant coatings, wear resistant coatings, corrosion resistant coatings, and / or other coatings. In these examples, assembly 112 may not be associated with an electrode (e.g., an anode or cathode).

[0097] Without departing from the spirit and scope of the present disclosure, many different arrangements of the various components depicted and the 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.

[0098] 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. An assembly for movably holding a component, the assembly comprising: A tool assembly, the tool assembly comprising: a tool base including a frame configured to hold the component and a guide associated with the multi-axis path; as well as a carrier movably coupled to the guide member; as well as A device is coupled to the carrier and movable along the multi-axis path with the carrier.

2. The assembly according to claim 1, wherein The multi-axis path is a helical path and the device is an electrode, wherein the device facilitates machining of the component.

3. The assembly of claim 1, wherein: The component is a blade segment having a plurality of blades; The device includes an electrode having a plurality of plates; as well as At least one of the plurality of plates is positionable along the multi-axis path adjacent at least one of the plurality of buckets.

4. The assembly according to claim 1, wherein: The carrier has a collar and a bent flange.

5. The assembly according to claim 4, wherein: The collar is configured to extend around the guide.

6. The assembly of claim 1, wherein: The guide includes a shaft and a helical key associated with the multi-axis path; and The carrier includes a collar configured to extend around the guide, and the carrier includes a keyway that receives the helical key.

7. The assembly according to claim 1, wherein: The frame includes a stop configured to limit movement of the carrier along the guide.

8. The assembly of claim 1, wherein: The component includes at least one tab.

9. The assembly according to claim 8, wherein: The at least one tab is removably attached to the tool base.

10. The assembly of claim 1, wherein: The carrier includes a clamp configured to be movably secured to the guide.

11. The assembly according to claim 2, wherein: The device is an anode and when the assembly is used to electroplate the component, the component forms at least a portion of a cathode.

12. An assembly for movably holding a component, the assembly comprising: A tool assembly, the tool assembly comprising: a tool base including a guide configured to hold the component, the guide including a shaft and a helical key associated with the helical path; as well as a carrier movably coupled to the guide, the carrier comprising a collar configured to extend around the guide, the collar comprising a keyway receiving the helical key; as well as An electrode is coupled to the carrier and is movable along the helical path with the carrier.

13. The assembly of claim 12, wherein: The component is a blade segment having a plurality of blades; The electrode has a plurality of plates; and At least one of the plurality of plates is positionable along the helical path adjacent at least one of the plurality of buckets.

14. The assembly of claim 12, wherein: The carrier has a curved flange.

15. The assembly of claim 12, wherein: The tool base includes a stop configured to limit sliding movement of the carrier along the guide.

16. The assembly of claim 12, wherein: The component includes at least one tab.

17. The assembly of claim 16, wherein: The at least one tab is removably attached to the tool base.

18. The assembly of claim 12, wherein: The electrode is an anode and, when the assembly is used to electroplate the component, the component forms at least a portion of a cathode.

19. A method for positioning a component relative to an electrode for an electrically driven plating process, the method comprising: Using a tool base to hold the component; a guide coupling a carrier to the tool base, the guide being associated with a multi-axis path; coupling the electrode to the carrier; and The carrier and electrode are moved relative to the component along the multi-axis path to position the electrode adjacent the component.

20. The method according to claim 19, wherein: The component is a bucket segment having a plurality of buckets, and the electrode has a plurality of plates that move relative to the plurality of buckets along the multi-axis path to position at least one of the plurality of plates adjacent to at least one of the plurality of buckets.

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