Sacrificial Cooling Hole Plug for Coating Bridge Prevention
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Solution Overview
Problem
Conventional sacrificial plug systems fail to effectively protect the configuration of cooling holes in components during post-formation processing, particularly from coating bridging and blocking, which can alter the size and shape of cooling holes, reducing their functionality and requiring rework.
Innovation Solution
A sacrificial plug system is integrally formed with the component and cooling holes, featuring a top portion for removal, a cover portion to control coating entry, and a connective member for secure engagement and easy severance from the cooling hole, preventing coating material from entering and bridging within the holes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional sacrificial plug systems are used, then cooling holes are left open during post-formation processing, but coating material enters and bridges the holes, altering their configuration
Solution Approach 1:
The sacrificial plug is integrally formed with the component during additive manufacturing, placing the protective element in position before the harmful coating process occurs. The plug remains in place throughout post-formation processing, preventing coating material from entering the cooling holes, and is only removed after all coating operations are complete.
Solution Approach 2:
The sacrificial plug acts as an intermediary protective element between the cooling holes and the coating material. It physically blocks the coating from bridging the holes while allowing the coating to be applied to surrounding surfaces, thus mediating the interaction between the harmful coating process and the sensitive cooling hole configuration.
2Reliability
If the sacrificial plug is integrally formed with the component, then protection is maintained throughout processing, but removal requires severing connective members
Solution Approach 1:
The sacrificial plug is designed with distinct segments including a top portion, a bottom portion, and connective members that link them. The connective members are specifically designed as separable elements that can be cleanly severed during removal, allowing the plug to be divided into removable sections while maintaining structural integrity during the protective phase.
Solution Approach 2:
The sacrificial plug is designed as a temporary protective element that is discarded after serving its purpose. The connective members are engineered to be easily severed and discarded, allowing clean removal of the plug from the component without damaging the cooling holes or requiring complex extraction procedures.
3Ease of operation
If the connective member is designed for easy severance, then removal is simplified, but structural integrity during processing may be compromised
Solution Approach 1:
The connective members exhibit local quality variations with different structural characteristics at different locations. The engagement portions have higher strength and rigidity to maintain secure attachment during processing, while the severance portions are designed with reduced cross-section or inherent weakness points that allow clean separation when removal force is applied.
Solution Approach 2:
The connective members transition from a rigid, strongly engaged state during processing to a separable state during removal. The design allows the connective members to maintain their structural role during the protective phase, then facilitate controlled separation when removal is initiated, adapting their mechanical behavior to the operational phase.
Data Source
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AI summary
Aspects of the embodiments set forth a sacrificial plug (100) system including a component having a surface (85) and at least one cooling hole (108) in the surface (85); a sacrificial plug (100) integrally formed with the component and integrally formed in the at least one cooling hole (108), where the sacrificial plug (100) includes a top portion (110); a cover portion (120); and a bottom portion, the bottom portion integrally formed, engaged to, and connected to at least one cooling hole (108). The sacrificial plug (100) system also includes at least one connective member (144) integrally formed with the bottom portion of the sacrificial plug (100) and integral with an inner wall (109) of each respective at least one cooling hole (108); each at least one connective member (144) being severable from the respective inner wall (109) when a force is applied to the top portion (110), thus permitting the sacrificial plug (100) to be removed from the at least one respective cooling hole (108).