Anodizable Blade Edge Micro-Arc Oxidation Coating
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing methods for attaching protective edges to composite turbine engine blades are complex, costly, and environmentally harmful, and do not adequately address the need for both erosion protection and aerodynamic smoothness.
Innovation Solution
A protective edge made of anodizable metal undergoes electrolytic micro-arc oxidation treatment to form a dense, hard coating with surface porosity, which is then polished on the external face for aerodynamic smoothness and left rough on the internal face for improved adhesion, facilitating attachment to the blade.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If intermediate layers (polyurethane film, bonding primer) are deposited to improve adhesion, then adhesion is improved, but manufacturing complexity and time increase
Solution Approach 1:
The patent removes the intermediate bonding layers (polyurethane film, bonding primer) from the assembly process. Instead of adding these separate adhesive layers, the protective edge is directly bonded to the composite blade through surface preparation alone, extracting the unnecessary intermediate components and simplifying the manufacturing process.
Solution Approach 2:
The patent applies preliminary surface preparation treatments (sandblasting, scraping, or grit blasting) to both the protective edge and the blade surface before bonding. This preliminary action creates optimally rough surfaces that provide immediate mechanical interlocking capability, eliminating the need for subsequent intermediate layer application and reducing overall manufacturing complexity.
2Strength
If intermediate layers are used to improve adhesion, then adhesion is improved, but manufacturing time increases
Solution Approach 1:
The patent eliminates the time-consuming intermediate layer application and curing processes by directly bonding the prepared surfaces. By removing these time-intensive steps, the overall manufacturing cycle time is significantly reduced while maintaining strong adhesion through proper surface preparation.
Solution Approach 2:
The surface preparation (sandblasting, scraping, or grit blasting) is performed in advance to create surfaces that are ready for immediate bonding. This preliminary action ensures that when bonding occurs, the surfaces are optimally prepared, eliminating the need for additional time-consuming intermediate steps and accelerating the overall manufacturing process.
3Strength
If intermediate layers are deposited to improve adhesion, then adhesion is improved, but environmental harm increases
Solution Approach 1:
The patent removes intermediate layers containing harmful substances (bonding primers, polyurethane films) from the manufacturing process. By eliminating these materials entirely and relying on mechanical surface preparation for bonding, the source of environmental contamination is extracted, preventing harmful substances from being introduced into the environment.
4Shape
If the protective edge is polished on the external face, then aerodynamic smoothness is improved, but adhesion capability decreases
Solution Approach 1:
The patent applies different surface treatments to different locations of the protective edge. The external face (aerodynamic surface) is polished to achieve smoothness for optimal airflow, while the internal bonding face is left rough through sandblasting or grit blasting to maximize adhesion. This local differentiation of surface quality allows both aerodynamic performance and bonding strength to be optimized simultaneously.
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 effective protection against erosion and impacts while ensuring a smooth aerodynamic surface and strong bonding, addressing the limitations of previous methods by enhancing both protection and attachment efficiency.
Implementation Method 1
this protection edge is subjected to an electrolytic micro-arc oxidation treatment, which is applied to both the inner and outer faces of the protection edge
Implementation Method 2
the formation of an oxide layer composed of the substrate's constituent elements
Implementation Method 3
the resulting coating exhibits a dense, hard core and a porous surface
Implementation Method 4
which is then polished on the external face for aerodynamic smoothness
Data Source
Figure 1~2
Figure 3~4
Figure 5
AI summary
The invention relates to a method of manufacturing a protective edge for a blade, wherein a protective edge (30) of anodizable metal is provided, and the protective edge (30) is subjected to a micro arc oxidation electrolytic treatment. The invention also relates to a protective edge (30) manufactured by said method.