Abrasive Sheath Brazing for Complex Turbine Component Surfaces
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Solution Overview
Problem
Current methods for applying abrasive layers to gas turbine engine components, such as electroplating, are limited by size and structural features of the targeted surface, require expensive equipment, and become cumbersome with complex masking/unmasking steps, necessitating a more efficient approach.
Innovation Solution
An abrasive sheath comprising a metallic layer of nickel foil or braze foil with an abrasive layer having a MCrAlY matrix and protruding abrasive particles, attached to the component surface through heat treatment such as welding or brazing, allowing for easier and more efficient application.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If electroplating methods are used to deposit abrasive layers on component surfaces, then the abrasive layer can be applied to protect the surface and enhance cutting/grinding strength, but the process becomes limited by the size or structural features of the targeted surface due to line of site or current density issues
Solution Approach 1:
A flexible substrate is introduced as an intermediary carrier that can be conformally coated with abrasive particles through dip-coating or spray application. The substrate acts as a mediator between the abrasive particles and the component surface, allowing the abrasive layer to be applied to complex geometries that would be inaccessible to direct electroplating methods.
Solution Approach 2:
The abrasive coating process is segmented into two independent steps: first coating the flexible substrate with abrasive particles, then attaching the substrate to the component surface. This segmentation allows each step to be optimized independently - the coating step can use simple dip or spray methods while the attachment step can accommodate various surface geometries.
2Reliability
If electroplating equipment is used for abrasive layer application, then the abrasive layer can be deposited, but relatively expensive equipment is required, particularly for plating applications on larger industrial parts
Solution Approach 1:
The flexible substrate serves as a mediator that can be coated using simple, low-cost dip-coating or spray equipment rather than expensive electroplating equipment. The substrate transfers the abrasively coated layer to the component surface, eliminating the need for costly plating facilities.
Solution Approach 2:
The flexible substrate can be a disposable or single-use component that is coated with abrasive particles and then attached to the component. This eliminates the need for expensive, reusable electroplating equipment while achieving the same functional result.
3Reliability
If electroplating techniques are used for abrasive layer application, then the abrasive layer can be deposited, but the process becomes complicated or cumbersome when dealing with larger parts and/or when complex masking/unmasking steps are required
Solution Approach 1:
The masking step is extracted and eliminated from the process. Instead of masking the component surface and then electroplating, the flexible substrate itself serves as the coating carrier that can be selectively attached to the component surface without requiring masks.
Solution Approach 2:
The flexible substrate acts as an intermediary that simplifies the coating process. It can be conformally coated without masks and then selectively attached to the component surface, eliminating the complex masking and unmasking steps required by direct electroplating methods.
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 method simplifies the attachment process, reduces processing time and labor costs, and eliminates the need for large electroplating equipment, enabling efficient abrasive layer application on complex or large surfaces.
Implementation Method 1
an exposed surface of the metallic layer being joinable to the component surface by a heat treatment comprising welding when the metallic layer consists of a nickel foil
Implementation Method 2
brazing when the metallic layer consists of a nickel braze foil
Implementation Method 3
an abrasive layer plated on a surface of the metallic layer and including a matrix comprising an alloy having the formula MCrAIY
Data Source
Figure 1~2
Figure 3~5
AI summary
An abrasive sheath for application to a component surface is disclosed. The abrasive sheath may comprise a metallic layer and an abrasive layer plated on a surface of the metallic layer. The abrasive layer may include a metal matrix and abrasive particles protruding from the matrix. An exposed surface of the metallic layer of the abrasive sheath may be joinable to the component surface by a heat treatment.