Coating Method for Gas Turbine Internal Surfaces
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current coating methods for gas turbine components are inefficient, prone to blockages, wasteful, costly, and contaminate furnace chambers, especially when coating internal surfaces with small apertures, such as cooling channels, due to residue buildup and the use of argon.
Innovation Solution
A coating method involving sealing apertures to form an enclosed space, heating under autogenous pressure with a composition containing metallic aluminum, halide activators, and organic polymers, and then unsealing to apply a uniform coating, reducing waste and contamination.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If current coating methods are used to coat internal surfaces with small apertures, then coating can be applied, but blockages occur and removal is difficult and costly
Solution Approach 1:
The patent seals the aperture before introducing the coating composition, preventing blockage during the coating process. This preliminary sealing action ensures that coating material cannot obstruct the aperture, eliminating the need for costly removal operations while maintaining coating application capability
2Ease of manufacture
If current coating methods are used, then coating can be applied to internal surfaces, but significant amounts of coating material are wasted
Solution Approach 1:
The patent extracts the coating composition from a separate container and introduces it into the enclosed internal surface space after sealing. This extraction approach ensures that coating material is delivered precisely where needed, eliminating waste from overspray or excess material that characterizes conventional coating methods
3Ease of manufacture
If current coating methods are used, then coating can be applied, but argon must be used which increases cost
Solution Approach 1:
The patent uses a disposable seal at the aperture that can be easily applied and removed. This simple, low-cost sealing mechanism replaces the need for expensive argon gas, achieving the same goal of preventing contamination and controlling the coating environment while dramatically reducing process costs
4Ease of manufacture
If current coating methods are used, then coating can be applied to internal surfaces, but furnace chambers become contaminated requiring periodic decontamination
Solution Approach 1:
The patent extracts the coating composition from a separate container and introduces it into the enclosed space after sealing. This extraction and containment approach prevents coating material from escaping into the furnace chamber, eliminating contamination while maintaining the ability to apply coating to internal surfaces
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
Improves coating uniformity, reduces blockages and waste, decreases costs, and minimizes furnace contamination, while enhancing heat tolerance and protection against reactive gases.
Implementation Method 1
The internal surface and the coating composition are heated under autogenous pressure, coating the internal surface with the coating composition
Implementation Method 2
The reservoir, the internal surface and the coating composition are heated under autogenous pressure, coating the internal surface with the coating composition
Data Source
Figure 1~3
Figure 4~6
Figure 7~9
AI summary
A coating method is disclosed including disposing a coating composition (200) into a fluidly communicating space (102) defined by an internal surface (104) of an article (100). The fluidly communicating space (102) includes at least one aperture (106), which is sealed, forming an enclosed space (204). The internal surface (104) and the coating composition (200) are heated under autogenous pressure, coating the internal surface (104) with the coating composition (200). The at least one aperture (106) is unsealed, re-forming the fluidly communicating space (102). Another coating method is disclosed in which the coating composition (200) is disposed into a reservoir (500) which is connected in fluid communication with the enclosed space (204) prior to heating under autogenous pressure, coating the internal surface (104) with the coating composition (200). Yet another coating method is disclosed in which the coating composition (200) and the article (100) are disposed in a vessel (700), which is sealed, forming the enclosed space (204) prior to heating under autogenous pressure, coating the internal surface (104) with the coating composition (200).