Digital Modeling for Ceramic Thermal Barrier Coating Thickness Estimation
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Solution Overview
Problem
Current methods for depositing ceramic thermal barrier coatings on gas turbine blades are inefficient due to reliance on iterative physical tests, which are costly and time-consuming, as they do not account for the complex shapes and movements of the blades during deposition, leading to inconsistencies in coating thickness.
Innovation Solution
A digital modeling method that estimates the thickness of ceramic thermal barrier coatings by representing the geometrical shape and movements of the hot part relative to the target, using a radiation model to calculate coating thickness at various points and instants, thereby adapting tooling and movements to achieve specified thicknesses more accurately.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If iterative physical tests are conducted to achieve specified coating thickness, then coating thickness specification is met, but manufacturing time and material resources increase significantly
Solution Approach 1:
The patent creates a digital copy (virtual model) of the blade and deposition process to simulate and predict coating thickness distribution. This virtual replica allows multiple test scenarios to be run without physical trial-and-error, eliminating the need for actual iterative physical tests while maintaining accuracy in predicting coating thickness specifications.
Solution Approach 2:
The patent performs preliminary calculations and simulations before actual deposition to determine optimal deposition parameters. By pre-calculating the coating thickness distribution based on the digital model and predicted radiation patterns, the actual deposition process can proceed directly to specification without iterative testing.
2Manufacturing precision
If iterative physical tests are conducted to achieve specified coating thickness, then coating thickness specification is met, but material resources are consumed excessively
Solution Approach 1:
The digital model serves as a virtual replica that allows unlimited simulation of deposition scenarios without consuming physical ceramic material. Multiple design iterations and parameter optimizations can be explored through simulation alone, eliminating the waste of ceramic material that would occur during iterative physical testing.
Solution Approach 2:
By performing all necessary thickness predictions and parameter optimizations in advance through digital simulation, the actual deposition process requires minimal to no material trial-and-error, thereby eliminating material waste associated with iterative physical tests.
3Loss of time
If digital modeling is used to estimate coating thickness, then manufacturing time is reduced, but measurement precision may be compromised without physical verification
Solution Approach 1:
The patent incorporates feedback mechanisms where the digital model is validated against limited physical measurements. The model predicts coating thickness distribution, and actual measurements from controlled test deposits are used to verify and refine the model's accuracy, ensuring that the digital estimation maintains high measurement precision while reducing overall test time.
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 approach reduces the need for iterative physical tests, allows for precise calculation of coating thickness at multiple points, and improves traceability, making it easier to achieve the desired coating specifications while minimizing material and time resources.
Implementation Method 1
The ceramic vapor is generated by evaporating 'target' bars of sintered ceramic that are bombarded by an electron beam
Implementation Method 2
The ceramic vapor is generated by evaporating 'target' bars of sintered ceramic
Implementation Method 3
the wall of the blade is coated by ceramic vapor condensing thereon
Implementation Method 4
The ceramic vapor is generated by evaporating 'target' bars of sintered ceramic that are bombarded by an electron beam
Data Source
AI summary
An estimation method for estimating thickness of a ceramic thermal barrier coating that is to be deposited by physical vapor deposition from at least one target and onto a gas turbine hot part mounted on a support tooling, the method including: digitally modeling a geometrical shape of the hot part and its movements relative to the target; representing the modeled hot part as a surface mesh; and estimating, for at least one mesh element of the hot part exposed to the radiation from the target during deposition of the coating, a coating thickness to be deposited on the mesh element at a given instant by using a radiation model modeling radiation from the target and taking account of the position of the mesh element at that given instant relative to the target.