Gas Turbine Airfoil Abrasive Coating With High Grit Loading
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Solution Overview
Problem
Existing abrasive coatings for gas turbine engine components face challenges in cost-effective implementation due to issues with dimensional control and frictional heating, particularly in polymer-based coatings used for rotating parts interacting with abradable seals.
Innovation Solution
A system for applying an abrasive coating comprising a polymer matrix and abrasive filler, with a high grit loading of 50%-75% by volume and low polymer content of 3%-10%, using a spray gun to deposit zirconia particles onto the component, allowing for porosity and gas escape during curing, and utilizing masking techniques for precise application.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If polymer based abrasive coatings are used to protect rotating parts, then corrosion and fatigue issues are eliminated, but dimensional control of liquid flow coating application deteriorates
Solution Approach 1:
The patent changes the physical state parameter of the coating material from liquid to solid particles. By using solid abrasive particles impregnated in a polymer matrix rather than liquid polymer coatings, the invention eliminates dimensional control issues associated with liquid flow while maintaining the corrosion and fatigue resistance benefits of polymer-based coatings.
2Strength
If high abrasive filler content is used in the coating, then wear resistance is improved, but coating applicability and dimensional control deteriorate
Solution Approach 1:
The patent creates a composite material structure where solid abrasive particles (50-75% by volume) are impregnated within a polymer matrix. This composite approach allows high abrasive filler content for improved wear resistance while the polymer matrix provides binding and facilitates coating applicability, resolving the contradiction between wear resistance and ease of manufacture.
3Productivity
If polymer matrix volume is reduced to allow high grit loading, then abrasive performance is improved, but coating integrity and curing issues worsen
Solution Approach 1:
The patent optimizes the polymer matrix volume to a specific range (25-50% by volume) that balances two competing requirements: sufficient polymer content to maintain coating integrity and enable proper curing, while allowing high grit loading (50-75% by volume) to maximize abrasive performance and productivity.
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
The solution provides a cost-effective, flexible, and efficient abrasive coating that maintains a desirable wear ratio with abradable seals, reducing frictional heating and wear, while allowing for high grit loading and precise deposition.
Implementation Method 1
the polymer matrix outgases during elevated temperature curing
Implementation Method 2
a spray gun from which a polymer matrix is atomized and propelled toward the component by an air jet such that grit particles are deposited onto the component
Data Source
AI summary
A component for a gas turbine engine includes an airfoil section including a free end and an abrasive coating sprayed onto the free end, the abrasive coating including a polymer matrix and an abrasive filler, the abrasive filler between about 50%-75% by volume of the abrasive coating.