Fiber Mesh Bond Coat for Gas Turbine Creep Resistance
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Solution Overview
Problem
Gas turbine blades experience creep due to oxidation and melting of bond layers under high temperatures, leading to reduced lifespan as the crept layers crack, limiting the usable life of the blades.
Innovation Solution
A porous substrate, such as a fiber mesh, is embedded between the bond layer and protective layers on the gas turbine blade to prevent and mitigate creep by providing a mechanical barrier and anchoring the viscous fluid layer, thereby reducing movement and extending the blade's lifespan.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a bond layer is applied to protect the gas turbine blade surface, then heat resistance and protection are improved, but creep occurs due to oxidation and melting under high temperatures, reducing blade lifespan
Solution Approach 1:
The patent applies a fiber mesh reinforcement to the bond layer, creating a composite structure that combines the protective properties of the bond layer with the mechanical strength and creep resistance of the fiber mesh. This composite approach prevents the bond layer from melting and creping under high temperatures while maintaining its protective function, thereby extending blade lifespan.
Solution Approach 2:
The fiber mesh used in the patent has a porous structure that allows it to be embedded within the bond layer while providing a three-dimensional reinforcement network. This porous configuration enables the fiber mesh to effectively resist creep forces without compromising the bond layer's protective capabilities, addressing both heat resistance and lifespan concerns.
2Reliability
If the bond layer is made thicker to provide better protection, then heat resistance is improved, but creep resistance decreases as the thicker layer is more prone to melting and cracking under high temperatures
Solution Approach 1:
By combining the bond layer with fiber mesh reinforcement, the patent creates a composite structure where the fiber mesh provides the necessary creep resistance even when the bond layer is sufficiently thick for heat protection. The fiber mesh acts as a skeletal framework that prevents the thicker bond layer from deforming or cracking under thermal stress.
Solution Approach 2:
The fiber mesh provides localized reinforcement at critical points within the bond layer, creating zones of enhanced creep resistance. This local quality enhancement allows the bond layer to maintain adequate thickness for heat protection while the fiber mesh specifically addresses creep vulnerability in high-stress areas.
3Strength
If a fiber mesh is embedded in the bond layer to prevent creep, then creep resistance is improved, but the complexity of the coating system increases
Solution Approach 1:
The porous structure of the fiber mesh allows it to be relatively simple in form while providing effective creep resistance. The mesh can be embedded in the bond layer using conventional coating processes, and the porous configuration enables the fibers to be properly distributed and anchored without requiring complex additional steps or materials.
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 use of a fiber mesh as a mechanical barrier effectively prevents creep, extending the lifespan of gas turbine blades with minimal additional cost by anchoring the bond coat material and providing a rough surface to resist movement of the protective layers.
Implementation Method 1
Gas turbine blades experience creep due to oxidation and melting of bond layers under high temperatures
Implementation Method 2
A porous substrate, such as a fiber mesh, is embedded between the bond layer and protective layers on the gas turbine blade to prevent and mitigate creep by providing a mechanical barrier and anchoring the viscous fluid layer
Data Source
AI summary
A gas turbine blade may have a bond coat applied to its surface. A porous substrate may be applied to the bond layer and one or more protective layers may be applied to the bond layer such that the fiber mesh is embedded between the bond layer and the protective layer to prevent creep.