Metal-Matrix Abrasive Coating Remelting for Smoother High-Temp Surfaces

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Solution Overview

Problem

Existing abrasive coatings with a metal matrix and ceramic abrasive particles, formed using electroplating or additive manufacturing, face limitations such as compatibility with low-temperature alloys and higher surface roughness, which reduces their effectiveness and durability in high-temperature applications.

Innovation Solution

The method involves additional processing of abrasive coatings using directed energy deposition to encapsulate abrasive particles further within a metal matrix and employing energy sources like lasers or plasmas to soften or melt the metal matrix, reducing surface roughness and enhancing uniformity, allowing the use of high-temperature alloys like nickel- or cobalt-based superalloys.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If electroplating or additive manufacturing is used to form abrasive coatings, then the coatings can be formed with metal matrix and ceramic abrasive particles, but the surface roughness increases and durability decreases

Engineering Contradiction:

Improvesurface roughnessVSAvoidcoating durability

Core Design Contradiction:

Manufacturing precisionVSReliability

Solution Approach 1:

The patent applies laser remelting to change the thermal and physical parameters of the coating surface, transforming the rough as-deposited surface into a smooth, dense surface through controlled melting and resolidification, thereby reducing surface roughness and improving coating durability

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent replaces mechanical finishing processes with laser-based thermal processing to achieve surface smoothing. The laser energy selectively melts and resolidifies the coating surface, eliminating the need for mechanical polishing or grinding operations

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Temperature

If traditional coating methods are used, then the process is simpler, but the coatings are limited to low-temperature alloys and cannot withstand high-temperature applications

Engineering Contradiction:

Improveservice temperature rangeVSAvoidcoating process complexity

Core Design Contradiction:

TemperatureVSEase of manufacture

Solution Approach 1:

The patent creates composite abrasive coatings by combining metal matrix materials (including high-temperature alloys like nickel-based superalloys) with ceramic abrasive particles, enabling the coating to withstand high-temperature applications while maintaining abrasive functionality

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

The patent employs directed energy deposition with laser heating to achieve precise temperature control during coating formation, enabling the use of high-temperature alloy materials that would be incompatible with traditional electroplating processes

Inventive Principle:

Principle #35Parameter changes

3Reliability

If abrasive coatings are applied to rotating components, then sealing efficiency improves, but the coating may cause damage to the rotating component

Engineering Contradiction:

Improvesealing efficiencyVSAvoiddamage to rotating component

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The laser remelting process changes the microstructural parameters of the coating, creating a denser, more uniform structure with reduced porosity and improved mechanical properties, which prevents coating material from being torn away and damaging the rotating component

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent replaces mechanical bonding methods with laser-based metallurgical bonding, creating a more robust coating-substrate attachment that resists the shear and tensile forces encountered during rotation, thereby preventing coating delamination and component damage

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

This approach improves the durability and effectiveness of abrasive coatings by reducing surface roughness, enhancing the encapsulation of abrasive particles, and extending their lifespan, while enabling their use in high-temperature systems by allowing the use of advanced alloys.

Implementation Method 1

employing energy sources like lasers or plasmas to soften or melt the metal matrix

Methodology Applied

Scientific EffectLaser heating: Laser

Implementation Method 2

employing energy sources like lasers or plasmas to soften or melt the metal matrix

Methodology Applied

Scientific EffectPlasma heating: Plasma

Implementation Method 3

additional processing of abrasive coatings using directed energy deposition to encapsulate abrasive particles further within a metal matrix

Methodology Applied

Scientific EffectDirected energy deposition: Laser Beam Welding

Data Source

PatentUS11612986B2Abrasive coating including metal matrix and ceramic particles

Publication Date: 2023.03.28 ROLLS ROYCE CORP

AI summary

A system may include a powder source; a powder delivery device; an energy delivery device; and a computing device. The computing device may be configured to: control the powder source to deliver metal powder to the powder delivery device; control the powder delivery device to deliver the metal powder to a surface of an abrasive coating; and control the energy delivery device to deliver energy to at least one of the abrasive coating or the metal powder to cause the metal powder to be joined to the abrasive coating.