Funnel-Concentrated Plasma Plume for Internal Cavity Coating

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Solution Overview

Problem

Ceramic and ceramic matrix composite materials used in high-temperature mechanical systems, such as gas turbine engines, face challenges with reactions to water vapor, leading to material recession and reduced mechanical properties, necessitating the development of effective environmental and thermal barrier coatings for internal cavities with complex geometries.

Innovation Solution

A plasma spray physical vapor deposition (PS PVD) system employing a funnel to direct a plasma plume into internal cavities, concentrating the plasma plume and enabling the formation of coatings on non-line of sight surfaces by aligning the funnel's outlet opening with the cavity opening, thereby focusing the energetic gas and coating material into the cavity.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If a plasma spray device is used to form coatings on internal cavity surfaces, then coating capability is improved, but the plasma plume width is too large to effectively coat small opening cavities

Engineering Contradiction:

Improvecoating uniformityVSAvoidplasma plume width

Core Design Contradiction:

Manufacturing precisionVSArea of stationary object

Solution Approach 1:

A funnel is introduced as an intermediary component between the plasma spray device and the internal cavity. The funnel has a wide inlet opening that receives the large plasma plume and a narrow outlet opening that directs a concentrated plasma jet into the cavity opening, effectively mediating the size mismatch between the plasma source and the target cavity

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The plasma plume transmission path is segmented into two stages: first, the large plasma plume is captured at the funnel inlet; second, the plasma is redirected through the narrow outlet as a focused jet. This segmentation allows the system to handle both large plasma sources and small cavity openings

Inventive Principle:

Principle #1Segmentation

2Manufacturing precision

If the plasma plume is directed into internal cavities with complex geometries, then coating coverage is improved, but the plasma plume disperses and coating uniformity deteriorates

Engineering Contradiction:

Improvecoating uniformityVSAvoidcavity geometry coverage

Core Design Contradiction:

Manufacturing precisionVSAdaptability or versatility

Solution Approach 1:

The system employs dynamic positioning where the funnel can be moved to different locations and orientations relative to the plasma spray device and the component. This allows the funnel outlet to be precisely aligned with various cavity openings of different geometries, maintaining focused plasma delivery adaptability across different cavity configurations

Inventive Principle:

Principle #15Dynamics

3Manufacturing precision

If the funnel outlet opening is made smaller to match cavity openings, then plasma concentration is improved, but the inlet opening size increases system complexity

Engineering Contradiction:

Improveplasma concentrationVSAvoidfunnel geometry

Core Design Contradiction:

Manufacturing precisionVSDevice complexity

Solution Approach 1:

The funnel geometry is defined by specific parameter relationships: the inlet opening diameter is substantially equal to the plasma plume width, while the outlet opening diameter is substantially equal to the cavity opening width. These parameter relationships optimize plasma concentration without requiring overly complex funnel designs

Inventive Principle:

Principle #35Parameter changes

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 PS PVD system effectively forms uniform coatings on internal cavity surfaces, enhancing environmental and thermal protection for components by reducing material reactions with the operating environment, thus extending the component's useful lifetime.

Implementation Method 1

plasma spray physical vapor deposition (PS PVD)... generating a plasma plume via a plasma spray device, wherein the plasma plume includes vaporized coating material

Methodology Applied

Scientific EffectPlasma spray physical vapor deposition: Physical Vapour Deposition

Implementation Method 2

The funnel may be used direct a larger volume of energetic gas carrying a feedstock material through a smaller opening in the internal cavity... the funnel is configured to reduce a width of the plasma plume from the inlet opening to the outlet opening

Methodology Applied

Scientific EffectPlasma plume concentration: Focusing

Implementation Method 3

a vaporized coating material in the plasma plume directed into the internal cavity by the funnel may form a coating on the surface(s) of the internal cavity

Methodology Applied

Scientific EffectPhysical vapor deposition: Physical Vapour Deposition

Data Source

PatentEP3640359B1Plasma spray physical vapor deposition within internal cavity

Publication Date: 2021.06.16 ROLLS ROYCE CORP

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AI summary

In some examples, a plasma spray physical vapor deposition system (10) includes a vacuum pump (24); a vacuum chamber (12); a coating material source (26); a plasma spray device (20) configured to generate a plasma plume (28) including vaporized coating material; and a funnel (30). The funnel (30) has an inlet opening (34) and an outlet opening (36) smaller than the inlet opening (34). The funnel (30) is configured and positioned to receive the plasma plume (28) through the inlet opening (34) and direct the plasma plume (28) out of the outlet opening (36).