CMC Aerodynamic Surface Machining for Coating Roughness Control

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

The formation process of ceramic matrix composites (CMCs) for gas turbine engine components, such as blades and vanes, is difficult and often results in surfaces that cannot be coated as needed for high-temperature and high-pressure environments, requiring messy manual machining with sub-optimal results.

Innovation Solution

A method involving autonomous adaptive machining is employed to identify and adjust the surface roughness of CMC components to specific levels, using robotic tools to either increase or decrease roughness as needed, followed by coating the exterior surfaces.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If manual machining is used to prepare CMC surfaces for coating, then surface roughness can be adjusted, but the process becomes messy and requires significant cleanup

Engineering Contradiction:

Improvesurface roughness controlVSAvoidmanufacturing cleanliness

Core Design Contradiction:

Manufacturing precisionVSEase of manufacture

Solution Approach 1:

The patent replaces manual mechanical machining with automated robotic machining systems. The robotic arm equipped with specialized machining tools performs precise surface roughness adjustment without the mess and cleanup requirements of manual machining, while maintaining control over surface roughness parameters for optimal coating preparation

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Manufacturing precision

If manual machining is used to prepare CMC surfaces, then surface roughness can be modified, but the results are sub-optimal

Engineering Contradiction:

Improvesurface roughness controlVSAvoidcoating quality

Core Design Contradiction:

Manufacturing precisionVSReliability

Solution Approach 1:

The patent implements a feedback control system where sensors continuously monitor the surface roughness during robotic machining. The system compares measured roughness values against target ranges and automatically adjusts machining parameters in real-time, ensuring optimal surface preparation for coating and eliminating the sub-optimal results associated with manual machining

Inventive Principle:

Principle #23Feedback

Solution Approach 2:

The patent utilizes programmable control of robotic machining parameters including speed, pressure, tool type, and motion patterns. By precisely controlling these parameters and making dynamic adjustments based on real-time feedback, the system achieves consistent optimal surface roughness that ensures reliable coating adhesion and quality

Inventive Principle:

Principle #35Parameter changes

3Manufacturing precision

If autonomous adaptive machining is implemented, then surface roughness can be precisely controlled, but device complexity increases

Engineering Contradiction:

Improvesurface roughness controlVSAvoidmachining system complexity

Core Design Contradiction:

Manufacturing precisionVSDevice complexity

Solution Approach 1:

The patent employs a multi-functional robotic machining system that can perform various surface preparation operations using different tools and techniques. The single robotic platform can switch between different machining approaches (abrasive, cutting, polishing) and adapt to different surface requirements, reducing the need for multiple specialized devices while maintaining precise control

Inventive Principle:

Principle #6Universality (Multi-functionality)

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 allows for the formation of CMC components with surfaces that are optimally prepared for coating, improving yield and reducing waste.

Implementation Method 1

machining the first sectors to increase the surface roughness to greater than the first roughness level and machining the second sectors to decrease the surface roughness to less than the second roughness level

Methodology Applied

Scientific EffectAbrasion: Abrasion

Data Source

PatentUS12583064B2Machining of ceramic matrix composite during preforming and partial densification

Publication Date: 2026.03.24 RTX CORP

AI summary

A method of forming an aerodynamic component for use in a gas turbine engine using ceramic matrix composites (CMCs) is provided. The method includes executing a full densification of the CMCs once a final shape of the aerodynamic component is achieved, identifying first and second sectors of an exterior surfaces of the aerodynamic component which have a surface roughness of less than a first roughness level and identifying second sectors of the exterior surface of the component which have a surface roughness of greater than a second roughness level, machining the first sectors to increase the surface roughness to greater than the first roughness level and machining the second sectors to decrease the surface roughness to less than the second roughness level.