CMC Aerodynamic Component Surface Roughness for Coating Adhesion
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Solution Overview
Problem
The formation process of ceramic matrix composite (CMC) components for gas turbine engines is difficult and results in surfaces that are either too smooth or too rough for effective coating, leading to sub-optimal results and messy manual machining.
Innovation Solution
A method involving autonomous adaptive machining to identify and adjust the surface roughness of CMC components to specific levels, using a robotic machining tool to increase or decrease roughness as needed, ensuring compatibility with coatings for high-temperature and high-pressure environments.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If manual machining is used to adjust surface roughness, then surface preparation can be performed, but the process is messy and requires significant cleanup
Solution Approach 1:
The patent replaces manual mechanical machining with an automated robotic system that applies coating material to the CMC component surface. The robotic applicator deposits coating in a controlled manner, eliminating the messy manual machining process while achieving the desired surface preparation for coating adhesion.
2Reliability
If the CMC surface is formed with high roughness, then coating adhesion may improve, but the surface becomes too rough for effective coating
Solution Approach 1:
The patent controls and optimizes the surface roughness parameters of the CMC component to fall within a specific range that is optimal for coating adhesion. Rather than making the surface excessively rough, the process adjusts the roughness parameter to the precise level needed for effective coating while maintaining a clean, manufacturable surface.
3Manufacturing precision
If the CMC surface is formed with low roughness, then the surface is smooth, but it cannot be effectively coated
Solution Approach 1:
The patent incorporates surface preparation as a preliminary step in the manufacturing process, where the CMC component surface is intentionally prepared with controlled roughness characteristics before coating application. This preliminary surface conditioning ensures the surface is optimally prepared for coating adhesion, preventing coating failure rather than attempting to correct it later.
4Reliability
If autonomous adaptive machining is used to adjust surface roughness, then coating compatibility is improved, but the device complexity increases
Solution Approach 1:
The patent replaces complex adaptive machining systems with a simpler robotic coating application system. Rather than using sophisticated sensors and adaptive control to modify the CMC surface geometry, the invention uses a robotic applicator that can precisely deposit coating material, achieving coating compatibility through controlled material application rather than complex surface modification.
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 the surface preparation of CMC components, enabling proper coating and reducing waste, thereby enhancing the performance and reliability of gas turbine engine components.
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
Data Source
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.