Additive Fuel Component Aluminide Coating for Coke Reduction
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Solution Overview
Problem
Additively manufactured hydrocarbon fuel contacting components in gas turbine engines face issues with carbonaceous deposit formation and adhesion due to rough surface finishes and high operating temperatures, leading to reduced efficiency and increased emissions.
Innovation Solution
A diffusion aluminide coating is applied to the components using a slurry composition, which is diffused into the surface to create a sublayer that acts as a coke barrier, and an additive sublayer is removed using an aqueous solution to smooth the surface and prevent coke deposits.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If additive manufacturing is used to fabricate fuel contacting components, then manufacturing flexibility and complexity handling are improved, but surface finish quality deteriorates with rough surfaces containing troughs and pits
Solution Approach 1:
A diffusion coating is applied to the additively manufactured component before final use. This preliminary coating step addresses the rough surface issue created by additive manufacturing, preparing the surface to resist coke formation before the component enters service.
Solution Approach 2:
A diffusion coating acts as an intermediary layer between the rough additively manufactured surface and the fuel. This intermediate coating smooths the effective surface and prevents direct contact between fuel and the rough troughs and pits, eliminating coke formation sites.
2Power
If high operating temperatures are used to increase engine efficiency, then energy output is improved, but coke formation rate increases
Solution Approach 1:
The diffusion coating, which could be seen as an additional manufacturing step, actually converts the high temperature operating condition into a benefit by creating a thermally stable, coke-resistant surface layer that thrives at elevated temperatures and prevents coke formation.
Solution Approach 2:
The diffusion coating changes the surface chemical composition and properties of the component. By altering the surface parameters through diffusion of coating materials, the surface becomes resistant to coke formation even at high operating temperatures.
3Reliability
If diffusion coating is applied to reduce surface roughness and prevent coke formation, then component durability is improved, but manufacturing process complexity increases
Solution Approach 1:
The diffusion coating process is self-regulating to some extent, where the coating diffuses into the substrate to form a gradient structure that is inherently resistant to coke formation. The process utilizes the thermal energy already present in the system to drive the diffusion, reducing the need for additional complex equipment.
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 reduces coke formation, improves surface finish, and extends the lifespan of fuel contacting components by preventing coke deposits and ensuring efficient fuel flow in gas turbine engines.
Implementation Method 1
The slurry is diffused into the surface of the component to create a diffusion aluminide coating comprising a diffusion sublayer on the component surface
Implementation Method 2
an additive sublayer is removed using an aqueous solution to smooth the surface
Data Source
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AI summary
A method for manufacturing a fuel contacting component that facilitates reducing coke formation on at least one surface of the fuel contacting component is disclosed herein. The method includes applying a slurry composition including a powder including aluminum to the component surface, wherein the fuel contacting component is formed by an additive manufacturing process. The slum' composition is heat treated to diffuse the aluminum into the component surface. The heat treatment comprises forming a diffusion aluminide coating on the component surface, wherein the diffusion coating comprises a diffusion sublayer formed on the component surface and an additive sublayer formed on the diffusion sublayer. The method further comprises removing the additive sublayer of the diffusion aluminide coating with at least one aqueous solution such that the diffusion sublayer and the component surface are substantially unaffected, wherein the diffusion layer facilitates preventing coke formation on component surface.