Wear-Resistant Coating for Gears Under Starved Lubrication

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Solution Overview

Problem

Components in gas turbine engines, particularly gears and bearings, experience high friction, increased contact temperatures, surface deterioration, excessive wear, and micro pitting due to high stress, leading to reduced durability and performance.

Innovation Solution

Application of a solid lubricant wear-resistant coating with a negative thermal expansion coefficient material dispersed within, combined with oleophilic and oleophobic coatings to regulate contact stress, retain lubricant, and conserve consumption, enhancing durability and lubrication efficiency.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If conventional coatings are applied to gear surfaces, then wear resistance is improved, but the coating cannot effectively retain lubricant under high stress conditions

Engineering Contradiction:

Improvewear resistanceVSAvoidlubrication efficiency

Core Design Contradiction:

StrengthVSReliability

Solution Approach 1:

The patent applies a porous coating material (such as porous ceramic or metal ceramic composite) on the gear surface. The porous structure provides numerous micro-cavities that can store and retain lubricant films under high stress conditions, preventing lubricant starvation and maintaining effective lubrication during gear operation.

Inventive Principle:

Principle #31Porous materials

Solution Approach 2:

The patent uses composite coating materials combining ceramic phases (such as alumina, silica) with metal matrices or organic binders. This composite structure provides both the wear resistance of ceramic materials and the lubricant retention capability through controlled porosity, simultaneously addressing both requirements.

Inventive Principle:

Principle #40Composite materials

2Reliability

If solid lubricant coating is applied, then lubrication under starved conditions is improved, but wear resistance under high stress is reduced

Engineering Contradiction:

Improvelubrication efficiencyVSAvoidwear resistance

Core Design Contradiction:

ReliabilityVSStrength

Solution Approach 1:

The patent employs composite coatings that integrate solid lubricant phases (such as MoS2, WS2, PTFE) within a wear-resistant ceramic or metal matrix. The solid lubricant particles provide low friction and lubrication under starved conditions, while the surrounding ceramic matrix maintains structural integrity and wear resistance under high stress loading.

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

The coating is designed with heterogeneous local properties where solid lubricant-rich regions provide lubrication where contact occurs, while ceramic-rich regions provide wear resistance in load-bearing zones. This spatial variation in composition allows simultaneous optimization of both lubrication and wear resistance.

Inventive Principle:

Principle #3Local quality

3Duration of action of stationary object

If thick coating is applied to enhance wear resistance, then durability is improved, but contact stress regulation capability is reduced

Engineering Contradiction:

ImprovedurabilityVSAvoidcontact stress regulation

Core Design Contradiction:

Duration of action of stationary objectVSStress or pressure

Solution Approach 1:

The patent optimizes the coating thickness to a specific range (typically 1-10 micrometers) that is thick enough to provide wear resistance and durability, but thin enough to allow stress regulation. The coating's mechanical properties (hardness, elasticity) are also adjusted through material selection and processing to enable effective contact stress regulation within this optimized thickness range.

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The porous structure of the coating allows it to deform and conform under contact loading, regulating stress distribution. The void spaces in the porous structure can compress under load, providing a cushioning effect that regulates contact stress while the overall coating thickness maintains durability.

Inventive Principle:

Principle #31Porous 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 coating provides enhanced wear resistance and lubrication under high stress conditions, improving performance under starved lubrication and higher temperature rise while reducing lubricant consumption.

Implementation Method 1

a solid lubricant wear resistant coating with a negative thermal expansion coefficient material dispersed within

Methodology Applied

Scientific EffectNegative thermal expansion: Negative Thermal Expansion

Implementation Method 2

oleophilic and oleophobic coatings to regulate contact stress, retain lubricant

Methodology Applied

Scientific EffectOleophilicity: Hydrophile

Implementation Method 3

oleophilic and oleophobic coatings to regulate contact stress, retain lubricant

Methodology Applied

Scientific EffectOleophobicity: Hydrophobe

Data Source

PatentUS12497681B2Coatings and coated component

Publication Date: 2025.12.16 GENERAL ELECTRIC CO

AI summary

A coated component includes a component having a surface, and a solid lubricant wear resistant coating on the surface, wherein the solid lubricant wear resistant coating includes a solid lubricant phase with a negative thermal expansion coefficient material dispersed therein. The component may also include a coating having oleophilic or porous properties disposed on portions thereof, and a coating having oleophobic properties disposed on portions thereof.