Fluoroelastomer Erosion Coating Repair for Jet Engine Cone Segments
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Solution Overview
Problem
Jet engine components suffer from erosion damage due to particulate matter, and existing fluoroelastomer erosion coatings require a method for repair or replacement to extend their useful life.
Innovation Solution
A method for repairing fluoroelastomer erosion coatings on jet engine components involves removing a portion of the existing coating, forming a cured replacement coating with a layer of fluoroelastomer and fibrous reinforcement, preparing and adhering it to the repair area, using mechanical and chemical methods for removal and curing, and ensuring proper alignment and bonding to prevent delamination.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If fluoroelastomer erosion coating is applied to protect engine components, then erosion resistance is improved, but the coating eventually deteriorates and requires repair
Solution Approach 1:
The patent applies the discarding and recovering principle by removing deteriorated portions of the fluoroelastomer coating and replacing them with fresh material. The repair process involves cutting away eroded sections, preparing the substrate, and applying new coating material to restore protective coverage, thereby extending the overall service life of the coating system.
Solution Approach 2:
The patent applies segmentation by dividing the coating repair into discrete sections rather than replacing the entire coating. Only the deteriorated portions are removed and replaced, allowing the intact portions to remain in service. This segmented approach reduces repair time and material consumption while maintaining erosion protection where needed.
2Reliability
If existing coating is removed and replaced, then coating durability is improved, but repair complexity increases
Solution Approach 1:
The repair process is segmented into distinct, manageable steps: removal of deteriorated coating, surface preparation, application of new material, and curing. Each step can be performed independently with specific tools and methods, making the complex overall process more controllable and repeatable.
Solution Approach 2:
The patent applies preliminary action by preparing the substrate surface before applying the new coating material. This includes cleaning, roughening, or chemically treating the surface to ensure proper adhesion of the new material to the substrate and to the remaining old coating, preventing future delamination.
3Ease of manufacture
If mechanical removal methods are used, then coating replacement is effective, but substrate damage risk increases
Solution Approach 1:
The patent replaces purely mechanical removal methods with chemical assistance. Chemical softening agents are applied to the deteriorated coating before mechanical removal, which softens the material and reduces the mechanical force needed for removal, thereby minimizing the risk of damaging the underlying substrate.
Solution Approach 2:
Chemical softening agents serve as intermediaries between the deteriorated coating and the mechanical removal process. These chemicals temporarily alter the properties of the old coating material, making it more pliable and easier to remove without aggressive mechanical forces that could damage the substrate.
4Strength
If adhesion preparation is performed, then bonding strength is improved, but repair time increases
Solution Approach 1:
Adhesion preparation is performed as a preliminary step before applying the new coating material. The substrate surface is cleaned, roughened, or chemically treated in advance to create optimal bonding conditions, ensuring strong adhesion when the new material is applied and reducing the need for rework.
Solution Approach 2:
The patent uses composite material structures where the new coating material is applied over a prepared substrate surface with potential intermediate layers. This composite approach ensures strong bonding between the old and new materials while maintaining the integrity and adhesion of the overall coating system.
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 method effectively extends the life of jet engine components by providing a durable and bonded fluoroelastomer erosion coating that withstands high-speed particulate impact, maintaining the engine's performance and reducing maintenance costs.
Implementation Method 1
the cured replacement erosion coating has a layer of fluoroelastomer and a layer of fibrous reinforcement
Implementation Method 2
Chemical softening of the existing fluoroelastomer coating may precede a mechanical method of removal
Implementation Method 3
adhering the prepared cured replacement erosion coating to the prepared repair area
Data Source
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AI summary
Disclosed is a method of repairing a rear cone segment (110) erosion coating including removing a portion of an existing fluoroelastomer coating from a rear cone segment to form a repair area (20); forming a cured replacement erosion coating corresponding to the repair area, wherein the cured replacement erosion coating has a layer of fluoroelastomer (44) and a layer of fibrous reinforcement (34); preparing the repair area and the cured replacement erosion coating for adhesion; locating the prepared cured replacement erosion coating on the prepared repair area; and adhering the prepared cured replacement erosion coating to the prepared repair area. Also disclosed is a cured replacement erosion coating and a repaired inlet nose cone.