Fan Blade Tip Abrasive Coating via Localized Softening
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Solution Overview
Problem
Existing methods for forming abrasive coatings on fan blade tips in gas turbine engines often result in heat generation and degradation of the substrate due to high temperatures, leading to inefficient grit capture and potential damage to the metal blade.
Innovation Solution
A method involving the use of a plasma spray gun to deposit molten aluminum powder onto the fan blade tip, creating a softened surface for grit particles to adhere to, while controlling deposition rate parameters to maintain optimal temperature and prevent substrate degradation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If high temperature is used to melt and deposit aluminum powder onto the fan blade tip, then the coating formation is effective, but the substrate metal properties are degraded and excessive heat is generated
Solution Approach 1:
The patent applies local quality by creating a temperature gradient where only the coating surface is heated to a softened state for grit capture, while the substrate remains cool. The plasma spray gun deposits aluminum powder that melts and forms a coating layer at controlled temperature, preventing substrate degradation while enabling effective grit particle adhesion to the softened coating surface.
Solution Approach 2:
The patent utilizes parameter changes by controlling the thermal state of the aluminum powder coating during deposition. The coating is heated to a specific temperature range where it becomes softened and receptive to grit particles, then rapidly cooled to lock in the grit capture. This dynamic temperature control allows effective coating formation without sustained high temperatures that would damage the substrate.
2Productivity
If the coating surface is softened to increase grit capture probability, then grit deposition efficiency improves, but substrate temperature control becomes more difficult
Solution Approach 1:
The patent applies preliminary action by pre-heating the aluminum powder coating to a softened state before grit particle deposition. The plasma spray process creates a molten or softened aluminum coating layer on the fan blade tip, which is then immediately receptive to grit particles. This preliminary softening of the coating surface ensures high grit capture efficiency while the rapid cooling that follows prevents substrate temperature rise.
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 method significantly increases grit capture efficiency, reducing heat generation and protecting the substrate, resulting in improved wear resistance and tolerance between fan blades and abradable liners.
Implementation Method 1
spraying the molten aluminum powder onto a spray plume area of the fan blade tip with a plasma spray gun to form a coating
Implementation Method 2
heating the aluminum powder until the aluminum powder is molten
Implementation Method 3
The softened surface greatly increases the probability of grit capture
Data Source
AI summary
A novel method of depositing grit particles onto a fan blade tip coating is provided. The method enhances grit capture by presenting a softened coating surface for the impinging particles. The softened surface is achieved without high substrate temperatures that could degrade the base metal properties in the fan blade. An auxiliary heat source is used to establish a locally heated and softened surface where the grit deposition takes place. The softened surface greatly increases the probability of grit capture.