Conforming Coating Mask for Turbine Cooling Hole Protection
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Solution Overview
Problem
Existing methods struggle to control the spray coating process around cooling holes in turbine components, leading to bridging issues that require rework and prolong processing time, especially in high-temperature environments where precise cooling hole functionality is crucial.
Innovation Solution
A conforming coating mask is contemporaneously formed via additive manufacturing with the turbine component, featuring self-biasing anchors, mask strips, and securing inserts that align with and cover cooling holes, preventing bridging by ensuring precise alignment and secure fit during coating processes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional masking methods are used during spray coating of turbine components, then coating application can proceed, but coating material enters cooling holes causing bridging issues that require rework
Solution Approach 1:
The mask is formed contemporaneously with the turbine component via additive manufacturing, positioning the mask strips over cooling holes before the coating process begins. This preliminary action prevents coating material from entering cooling holes during spray coating, eliminating bridging issues and the need for rework.
Solution Approach 2:
The mask acts as an intermediary element between the spray coating process and the cooling holes. The mask strips are positioned to cover cooling holes, and the securing inserts engage with the cooling holes to hold the mask in place, thereby preventing direct contact between coating material and cooling holes.
2Manufacturing precision
If conventional masking methods are used, then coating can be applied, but the mask fails to secure properly around complex turbine geometries leading to poor alignment
Solution Approach 1:
The mask is additively manufactured contemporaneously with the turbine component, allowing the mask geometry to be precisely tailored to match the specific turbine component geometry. This preliminary design and manufacturing step ensures proper alignment with cooling holes while accommodating complex turbine shapes.
Solution Approach 2:
The mask structure features localized elements including mask strips positioned over specific cooling holes and securing inserts engaged with specific cooling holes. Each element is designed with specific properties (mask strip coverage, insert engagement) tailored to its local function, allowing the mask to adapt to complex turbine geometries while maintaining precise alignment.
3Manufacturing precision
If the mask is removed after coating, then the coating process is complete, but bridges form between the component surface and mask edge requiring rework
Solution Approach 1:
The mask is positioned and secured over cooling holes before the coating process begins. This preliminary positioning ensures that the mask edges are properly located relative to the component surface and cooling holes throughout the coating process, preventing bridge formation that would require rework.
Data Source
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AI summary
A conforming coating mask (300) is used with a turbine component having a plurality of cooling holes (201). The conforming coating mask (300) includes at least two anchors (301, 310); a plurality of radial mask strips (303) integrally formed with and extending between each of the at least two anchors (301, 310); and at least one coating mask securing insert (330). Each at least one coating mask securing insert (330) integrally formed with a respective at least one radial mask strip (303); wherein the plurality of radial mask strips (303) align with and cover the plurality of cooling holes (201).