Airfoil Masking System for Coating Precision
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
In gas turbine engines, precise control of working fluid flow across airfoil tip sections is challenging due to flow losses, clearance, temperature, and efficiency concerns, which are exacerbated by the need for accurate and efficient coating systems that are resistant to abrasion and thermal erosion.
Innovation Solution
A masking system for airfoils featuring locator and mask sections that conform to convex and concave surfaces, utilizing locator pins and retainer tabs to position and retain mask sections along the airfoil edges, ensuring accurate coverage and protection during coating processes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional coating systems are used on airfoil surfaces, then thermal and erosion resistance is improved, but coating accuracy and precision deteriorate due to difficulty in masking complex airfoil geometries
Solution Approach 1:
The mask is divided into multiple sections (first mask section for convex surface, second mask section for concave surface) that can be independently positioned and secured. Each mask section has dedicated positioning features (locator pins, retainer tabs) that enable precise placement on specific geometric features of the airfoil, thereby achieving accurate coating application on complex surfaces.
2Manufacturing precision
If complex masking systems are designed to achieve precise coating coverage, then coating accuracy is improved, but device complexity and processing time increase
Solution Approach 1:
The positioning features (locator pins, retainer tabs) and masking surfaces are integrated into a unified mask structure that simultaneously addresses both positioning accuracy and coating coverage. The mask sections combine multiple functions (positioning, retaining, and masking) in single components, reducing the number of separate elements needed while maintaining precision.
3Ease of manufacture
If conventional masking methods are used, then ease of manufacture is maintained, but processing time and scrap rates increase due to reworking
Solution Approach 1:
The mask sections are pre-positioned using locator pins that engage with predetermined locations on the airfoil, and pre-secured using retainer tabs that engage with corresponding features. This preliminary positioning and securing action ensures accurate coating coverage from the first attempt, eliminating the need for reworking and reducing scrap rates.
Data Source
AI summary
A masking system for an airfoil comprises a locator for positioning along the trailing edge of the airfoil, and first and second mask sections. The first mask section has a trailing edge portion with locator pins for cooperating with a positioning tab on the locator to position the first mask section along the trailing edge of the airfoil, and a leading edge portion for extending around the leading edge of the airfoil to locate the first mask section along the convex surface. The second mask section has a retainer portion for cooperating with a retainer process on the first mask section to retain the second mask along the leading edge of the airfoil, and a flange portion for extending between the locator pins to locate the second mask along the concave surface.