Guided Grinding Tool for Interior Thermal Barrier Coating Removal
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
In gas turbine systems, thermal barrier coatings (TBCs) on components can be damaged due to expansion caused by high operational temperatures, requiring removal but existing methods necessitate costly and time-consuming off-site servicing.
Innovation Solution
A tool and method for in situ removal of TBCs from interior surfaces of components, utilizing a rotary device with a grinding attachment and wheel assembly to carefully remove and polish the coating, allowing for on-site operation and reduced downtime.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of time
If TBC removal is performed using existing methods, then the coating can be removed, but the process requires off-site servicing which increases downtime and cost
Solution Approach 1:
The tool enables the component to be serviced in situ without requiring removal to an external facility. The self-contained design with integrated grinding attachment, coolant delivery, and waste removal allows the system to perform the TBC removal operation where it is needed, eliminating transportation and setup time at external facilities.
Solution Approach 2:
The tool is divided into functional modules including a rotary device with grinding attachment, coolant delivery system, and waste removal mechanism. This segmentation allows each component to perform its specific function efficiently while maintaining overall system portability and ease of operation in the field.
2Productivity
If a rotary grinding device is used to remove TBC, then removal efficiency increases, but control over cutting depth and precision becomes more difficult
Solution Approach 1:
The tool incorporates a coolant delivery system that provides real-time cooling and lubrication during the grinding process, allowing operators to monitor and adjust cutting parameters. The coolant flow rate and temperature provide feedback on the grinding intensity, enabling precise control over material removal rate and cutting depth while maintaining high productivity.
3Loss of time
If in situ TBC removal is implemented, then downtime is reduced, but the tool complexity and initial cost increase
Solution Approach 1:
The tool is designed as a multi-functional system that combines TBC removal, cooling, and waste removal capabilities in a single portable unit. This universal design consolidates multiple operations that would otherwise require separate equipment and procedures, reducing overall system complexity while enabling comprehensive in situ servicing.
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
Enables efficient and timely removal of TBCs on-site, reducing downtime from months to weeks or days, and preventing further damage by allowing for controlled removal and polishing of the coating.
Implementation Method 1
a grinding attachment attached to the rotary device
Implementation Method 2
a wheel assembly coupled to the tool holder for guiding the tool holder about an interior perimeter of the component
Data Source
AI summary
A tool for removing a coating from an interior surface of a component. The tool includes a rotary device; a grinding attachment attached to the rotary device; a tool holder configured to: set an axial position of the grinding attachment coupled to the rotary device over the coating on the interior surface of the component; and set a radial position of the grinding attachment coupled to the rotary device, the radial position defining a cutting depth of the grinding attachment into the coating on the interior surface of the component; and a wheel assembly coupled to the tool holder for guiding the tool holder about an interior perimeter of the component.