Aluminide Coating Roughness for Gas Turbine Aerodynamic Efficiency
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Solution Overview
Problem
Conventional gas turbine engine components rely on complex airfoil shapes to optimize aerodynamic lift, which introduces manufacturing complexity and limited aerodynamic efficiency improvements.
Innovation Solution
A method of forming an aluminide coating with targeted surface roughness on gas turbine engine components by dispersing particles on the airflow surface, using a deposition process that includes a silicon-containing layer and a metal donor material, resulting in a surface finish that differs between convex and concave airflow surfaces, increasing roughness on the convex surface to enhance aerodynamic efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If complex airfoil shapes are used to optimize aerodynamic lift, then aerodynamic efficiency is improved, but manufacturing complexity increases
Solution Approach 1:
The patent applies different surface roughness characteristics to different regions of the airfoil surface. Specifically, the convex airflow surface is given a rougher finish (Ra 32-128 microinches) while the concave surface maintains a smoother finish (Ra 8-32 microinches). This local differentiation optimizes aerodynamic performance without requiring complex overall geometry changes.
Solution Approach 2:
Instead of modifying the three-dimensional airfoil geometry to improve lift, the patent introduces surface roughness as an additional dimensional characteristic. By controlling the texture and roughness of the surface in the micro-scale dimension, the patent achieves aerodynamic improvements without changing the macro-scale airfoil shape.
2Productivity
If complex airfoil shapes are used to optimize aerodynamic lift, then aerodynamic efficiency is improved, but the improvement in aerodynamic efficiency is ultimately limited
Solution Approach 1:
The patent changes the surface roughness parameter (Ra value) to achieve aerodynamic improvements. By adjusting the roughness from smooth (Ra 8-32) to rough (Ra 32-128) on the convex surface, the patent creates a controllable parameter that directly influences airflow characteristics and lift generation, providing a reliable method for optimization.
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 method improves aerodynamic efficiency of gas turbine engine components without requiring complex geometries, providing enhanced lift beyond geometry-based improvements by creating a surface finish that slows airflow velocity on the convex surface compared to the concave surface.
Implementation Method 1
One suitable deposition environment relies on vaporizing a donor material including a metal effective to form the aluminide layer, which includes the metal from the donor material, silicon from the layer, and the particles from the layer
Implementation Method 2
a deposition process that includes dispersing the particles on at least the portion of the airflow surface and then forming the aluminide coating that includes the dispersed particles in a substantially intact condition
Data Source
AI summary
A gas turbine engine component (10) with an aluminide coating (42) on at least a portion of an airflow surface (18) that includes a roughening agent (44) effective to provide a desired surface roughness and a deposition process for forming such aluminide coatings (42). A layer (40) including a binder (38) and the roughening agent (44) maybe applied to the superalloy substrate (46) of the component (10) and the aluminide coating (42) formed on the airflow surface portion by exposing the component (10) and layer (40) to an appropriate deposition environment. Suitable roughening agents include metal and ceramic particles (44) that are dispersed on the airflow surface portion before exposure to the deposition environment. The particles (44), which are substantially intact after the aluminide coating (42) is formed, are dispersed in an effective number to supply the desired surface roughness.