Coating System Cooling Hole Obstruction Prevention
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Solution Overview
Problem
Conventional thermal spray coating methods often block cooling holes in turbomachinery components, requiring costly and labor-intensive processes to clear obstructions, and can result in an over-cooled component that poorly bonds with the coating, leading to potential degradation.
Innovation Solution
A system that includes a control system coupled with a coating robot, which selectively forces air through cooling holes during the coating process using a rotary air slip ring, allowing the component to rotate freely and preventing obstruction while maintaining optimal temperature for better bonding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If thermal spray coating is applied to turbomachinery components, then coating coverage is improved, but cooling holes become obstructed
Solution Approach 1:
Air is forced through the cooling holes before coating application to clear any potential obstructions and establish a clear path. This preliminary action prevents coating material from blocking the holes during the subsequent coating process
Solution Approach 2:
A gas stream (air or inert gas) is used as an intermediary substance to protect the cooling holes from coating material. The gas flow creates a barrier that prevents thermal spray particles from entering and obstructing the cooling holes while allowing the coating to be applied to the component surface
2Object-affected harmful factors
If air is forced through cooling holes during coating, then cooling hole obstruction is prevented, but component temperature decreases
Solution Approach 1:
Air flow through the cooling holes is applied periodically or intermittently during the coating process rather than continuously. This allows the component temperature to be maintained at optimal levels for coating adhesion while still preventing hole obstruction during critical coating phases
Solution Approach 2:
The parameters of air flow (flow rate, pressure, duration) are carefully controlled and adjusted to achieve the minimum necessary flow to prevent obstruction without causing excessive cooling. The system optimizes the balance between hole clearance and temperature maintenance
3Manufacturing precision
If component rotates freely during coating, then coating uniformity is improved, but air supply to cooling holes becomes complex
Solution Approach 1:
The air supply system is designed with localized delivery points that track with the component rotation. Air nozzles or channels are positioned to deliver gas flow directly to the cooling holes regardless of the component's rotational position, maintaining simplicity while enabling free rotation
Solution Approach 2:
A rotary joint or flexible coupling mechanism serves as an intermediary between the stationary air supply and the rotating component. This allows the component to rotate freely while maintaining a continuous, simple air supply connection to the cooling holes
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 efficiently coats turbomachinery components without obstructing cooling holes, improving the quality of the thermal barrier coating and reducing the need for costly clearance processes, thereby enhancing the durability and performance of the coating.
Implementation Method 1
an airflow system configured to force air through the component during application of the thermal coating material
Implementation Method 2
application of a thermal coating material to a component
Data Source
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AI summary
A system (2) according to various embodiments can include: a coating system (10) configured to apply a thermal coating material (12) to a component (14), the component (14) having a plurality of cooling holes (16); an airflow system (20) coupled with the coating system (10), the airflow system (20) configured to force air through the component (14); and a control system (40) coupled with the airflow system (20) and the coating system (10), the control system (40) configured to: detect coating instructions (42) for the coating system (10), the coating instructions (42) instructing (42) the coating system (10) to apply the thermal coating material (12) to a subset (16A, 16B) of the plurality of cooling holes (16); and instruct the airflow system (20) to force air through the subset (16A, 16B) of the plurality of cooling holes (16) during application of the thermal coating material (12) to the component (14) in response to detecting the coating instructions (42).