Geometrically Segmented Thermal-Insulation Coating Against Spallation
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Solution Overview
Problem
Existing thermal insulation coatings in gas turbine engines suffer from spallation due to severe operating environments, leading to increased maintenance costs and reduced durability.
Innovation Solution
A geometrically segmented thermally insulating topcoat with surface features, such as pyramids, is applied over a substrate, featuring faults that extend through the coating to dissipate internal stresses and prevent spallation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a thermal insulation coating is applied to protect components from high temperatures, then component durability is improved, but the coating is prone to spallation in severe operating environments
Solution Approach 1:
The coating is divided into segmented portions separated by faults that extend through the thermal insulation coating from the surface feature tip. This segmentation allows the coating to accommodate thermal stresses and strain without spalling, while maintaining thermal insulation performance.
Solution Approach 2:
Surface features with tips are formed on the substrate before applying the thermal insulation coating. These pre-formed features create predetermined fault locations that guide crack propagation away from the coating-substrate interface, preventing spallation before it occurs.
2Stability of the object's composition
If geometrically segmented coating is used to prevent spallation, then coating stability is improved, but manufacturing complexity increases
Solution Approach 1:
The segmentation structure is self-formed during the coating application process. As the thermal insulation coating is deposited over the surface features, the coating naturally forms segmented portions separated by faults extending from the surface feature tips, eliminating the need for post-processing segmentation steps.
Solution Approach 2:
The surface feature geometry parameters (tip shape, size, spacing) are optimized to control fault formation and segmentation characteristics. By adjusting these parameters, the coating achieves desired stability without requiring complex manufacturing processes.
Data Source
AI summary
A process of preventing spallation for a geometrically segmented thermally insulating top coat on an article, the process including forming a surface feature with a surface feature tip on a surface of the article; disposing the thermally insulating topcoat over the surface feature; and forming segmented portions that are separated by faults extending through the thermally insulating topcoat from the surface feature tip.