Hole Resizing via Thermal Diffusion Coating

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Solution Overview

Problem

Existing methods for resizing premix fuel supply holes in gas turbine fuel nozzle assemblies are costly and time-consuming, often requiring techniques like welding that can damage complex components.

Innovation Solution

A method involving a composition of an aluminum alloy with a melting temperature higher than aluminum is applied to the interior surface of the holes, and then heated to allow metal diffusion and reaction, forming a coating that reduces the cross-sectional area without damaging the components.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If conventional welding or plug insertion methods are used to resize holes, then the hole size can be reduced, but the component may be damaged and the process becomes costly and time-consuming

Engineering Contradiction:

Improvehole size controlVSAvoidcomponent damage

Core Design Contradiction:

Manufacturing precisionVSObject-affected harmful factors

Solution Approach 1:

The patent changes the physical-chemical parameters of the coating material by using aluminum alloys with controlled melting temperatures higher than pure aluminum. This allows the coating to remain stable during the heating process while the base metal diffuses into it, resizing the hole without damaging the component structure.

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent utilizes phase transitions of the aluminum alloy coating during controlled heating. The coating melts and solidifies in a controlled manner, allowing metal diffusion to occur while maintaining component integrity. This phase transition enables hole resizing without the damaging effects of welding.

Inventive Principle:

Principle #36Phase transitions

2Manufacturing precision

If welding techniques are used to resize holes, then hole size can be modified, but the process becomes expensive and time-consuming

Engineering Contradiction:

Improvehole size controlVSAvoidrepair time

Core Design Contradiction:

Manufacturing precisionVSLoss of time

Solution Approach 1:

The patent replaces mechanical welding processes with a thermal diffusion coating process. Instead of using welding to resize holes, a coating is applied and then heated to enable controlled metal diffusion, which achieves the same hole resizing effect without the time-consuming and expensive welding operation.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Manufacturing precision

If plugs are inserted and new holes are formed, then hole size can be reduced, but the process complexity increases and component integrity may be compromised

Engineering Contradiction:

Improvehole size controlVSAvoidprocess complexity

Core Design Contradiction:

Manufacturing precisionVSDevice complexity

Solution Approach 1:

The patent applies the coating to the interior surface of the hole before any heating or diffusion processes occur. This preliminary coating application ensures that the hole resizing is achieved in a single controlled process rather than through multiple steps involving plug insertion and re-drilling, thereby reducing process complexity.

Inventive Principle:

Principle #10Preliminary action

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

This method effectively resizes the holes, avoiding costly and damaging techniques like welding, while maintaining the integrity of the components and achieving precise flow rate adjustments.

Implementation Method 1

heating the component to cause a metal within the component to diffuse from the component into the composition and react with the aluminum alloy in the composition to form a coating

Methodology Applied

Scientific EffectDiffusion: Diffusion

Implementation Method 2

react with the aluminum alloy in the composition to form a coating on the interior surface of the hole

Methodology Applied

Scientific EffectChemical reaction: Chemical Bonding

Data Source

PatentUS9187816B2Methods of resizing holes

Publication Date: 2015.11.17 GE INFRASTRUCTURE TECH LLC

AI summary

Methods of reducing an initial cross-sectional area of a hole in a component to a predetermined cross-sectional area including preparing a composition comprising at least an aluminum alloy with a melting temperature higher than aluminum, applying the composition to an interior surface of the hole, and then heating the component to cause a metal within the component to diffuse from the component into the composition and react with the aluminum alloy in the composition to form a coating on the interior surface of the hole. The heating step is performed to selectively modify the initial cross-sectional area of the hole and thereby directly attain the predetermined cross-sectional area thereof.