Coating Fixture for Turbine Vane Clusters
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Solution Overview
Problem
The application of coatings to gas turbine engine components, particularly vane clusters, is hindered by the geometry of stator vanes, leading to non-uniform coating distribution and thermal mismatch due to 'hidden' areas not receiving adequate coating thickness, even with non-line of sight methods like EB-PVD.
Innovation Solution
A fixture comprising two masks, each with a mask shroud and platform, is used to ensure equal geometry and spacing of mask vanes relative to the vane cluster, allowing for consistent coating application across all surfaces, including 'hidden' areas, using processes like electron beam physical vapor deposition.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If non-line of sight coating application methods (such as EB-PVD) are used, then coating can be applied to vane cluster surfaces, but the vane cluster geometry creates mask effects that reduce coating thickness on hidden faces and create non-uniform coating distribution
Solution Approach 1:
A mask assembly is introduced as an intermediary component between the coating source and the vane cluster. The mask assembly includes a mask platform, mask shroud, and mask vanes that are positioned to control coating material deposition. The mask vanes are configured with specific geometries and spacing to allow coating material to reach the hidden faces of the vane cluster while preventing excessive deposition on exposed areas, thereby achieving uniform coating thickness across all surfaces including those previously difficult to reach.
2Productivity
If vane clusters are used to reduce part count and weight, then manufacturing efficiency improves, but the clustered geometry interferes with uniform coating application on adjacent airfoils
Solution Approach 1:
The mask assembly serves as a mediating structure that enables uniform coating application on vane clusters without requiring disassembly or repositioning of components. The mask platform is positioned to support the mask shroud and mask vanes in precise locations that correspond to the vane cluster geometry, allowing coating material to be deposited uniformly on all airfoils in the cluster simultaneously, thus maintaining manufacturing efficiency while achieving coating uniformity.
Solution Approach 2:
The mask vanes are designed with varying geometries and spacing configurations tailored to the specific local requirements of different areas of the vane cluster. The mask structure provides different levels of protection and guidance for coating material deposition in different zones, ensuring that each area receives the appropriate amount of coating material based on its geometric characteristics and accessibility.
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 ensures increased coating thickness uniformity across vane surfaces, enhancing thermal and corrosion resistance, and reducing thermal gradients within the engine.
Implementation Method 1
non-line of sight coating application methods, such as electron beam physical vapor deposition (EB-PVD), are used
Data Source
AI summary
The present disclosure relates generally to a fixture for use in applying a coating to a multiple vane nozzle for use in a turbomachine. The fixture includes first and second masks that are applied to opposite sides of the nozzle to mimic the geometry and spacing of the vanes of the nozzle.