Electroplating Component Securing System with Spring Insert
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Solution Overview
Problem
The traditional masking process for gas turbine engine components during electroplating is labor-intensive, time-consuming, and costly, requiring extensive manual handling and complex tooling, which increases the risk of component damage and reduces efficiency.
Innovation Solution
A system comprising a main body with a retention slot, a fastener, and an insert with a flat spring, which securely holds the component in place and maintains electrical contact, allowing for rapid and efficient masking and electroplating processes, with components such as turbine blades and vanes being secured using additive manufacturing techniques for rapid tool production.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional masking process is used for gas turbine engine components during electroplating, then the component surfaces can be protected from coating, but the process becomes labor-intensive, time-consuming, and costly with increased risk of component damage
Solution Approach 1:
The component itself serves as the masking tool by utilizing its geometric features (such as dovetail slots and external contours) to define the masking boundaries. The masking material is applied directly to the component surface without requiring separate masking tools, allowing the component to mask itself during the electroplating process. This eliminates the need for complex external masking apparatus and reduces handling operations.
Solution Approach 2:
The masking function is extracted from separate masking tools and integrated directly into the component surface through applied masking material. By removing the need for additional masking devices and reducing handling steps, the process achieves faster processing while maintaining reliable component protection during electroplating.
2Manufacturing precision
If complex tooling is used to hold and manipulate components during electroplating, then precise positioning and electrical contact can be maintained, but the cost increases and the risk of component damage increases due to extensive manual handling
Solution Approach 1:
The component's geometric features serve multiple functions: they provide structural support, define masking boundaries, and ensure consistent electrical contact during electroplating. The masking material applied to the component surface simultaneously protects areas from coating while allowing electrical contact through designated regions. This multi-functionality eliminates the need for separate positioning fixtures and masking tools, reducing overall system complexity and cost.
Solution Approach 2:
The component itself provides the electrical contact interface through its geometric features rather than requiring external fixtures. The masking material is applied directly to the component surface, allowing the component to maintain its own positioning and electrical connection during the electroplating process. This self-service approach reduces the need for complex external tooling while maintaining manufacturing precision.
3Reliability
If traditional masking materials and methods are used, then component surfaces can be protected, but extensive manual handling is required which increases processing time and cost
Solution Approach 1:
A masking material in the form of a flexible film or coating is applied directly to the component surface. This thin film conformally follows the component's geometry, providing reliable surface protection while being easily applied and removed. The flexible nature of the masking material allows it to adapt to complex component shapes without requiring rigid masking tools, thereby reducing application time and manual handling.
Solution Approach 2:
The masking function is extracted from complex rigid masking tools and implemented through a simple flexible film or coating applied directly to the component. This extraction simplifies the masking process, reducing both the time required for application and the manual handling involved, while maintaining reliable surface protection during electroplating.
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
The system significantly reduces manual handling and processing time, lowers costs, and ensures consistent electroplating by maintaining electrical contact during high-temperature processes, thereby extending component life and reducing the likelihood of damage.
Implementation Method 1
an insert (380) inserted into a channel (520) of the main body (302). The insert (380) is configured to maintain electrical contact between the shank (360) and the component (400) when the component (400) is retained within the retention slot (313)
Implementation Method 2
The application of platinum composite coatings to turbine airfoils creates a highly refractory and temperature resistant component with increased hot corrosion resistance and reduced oxidation levels
Data Source
AI summary
A system for securing a component for an electrically-driven process is disclosed. The system includes a mai015134n body having an opening, a retention slot configured for retaining the component, and a channel. The system includes a fastener extending through the opening in the main body, and an insert inserted into the channel. The system has a shank movably coupled to the fastener and configured to contact the insert. The insert is configured to maintain electrical contact between the shank and the component when the component is retained within the retention slot.