Impingement Part Cooling for Thermal Spray Coating
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Solution Overview
Problem
Existing cooling devices for thermal spray coating processes are inconsistent in maintaining component temperature, leading to erratic thermal coating results due to sensitivity to slight changes in coating parameters, especially when dealing with components of varying sizes.
Innovation Solution
A cooling device with a manifold having multiple impingement holes less than one-eighth inch in diameter, positioned close to the component surface, which directs high-velocity cooling air to maintain consistent component temperature, eliminating the need for air amplifier blowers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If low velocity, high volume air nozzles are used for cooling, then high air flow rate is achieved, but thermal coating results become erratic due to sensitivity to parameter changes
Solution Approach 1:
The invention changes the parameters of cooling air delivery by using high velocity (supersonic) flow instead of low velocity flow, and by using a shock wave-induced impingement mechanism instead of direct nozzle-to-surface flow. This transforms the cooling mechanism from being sensitive to flow rate variations to being controlled by shock wave physics, resulting in more consistent temperature control and reliable thermal coating results.
2Quantity of substance
If air amplifier blowers are used to generate high flow rate cooling air, then cooling capacity is increased, but device complexity and air consumption increase
Solution Approach 1:
The invention replaces the mechanical air amplifier blower system with a passive shock wave-based impingement mechanism. The cooling air is delivered through a nozzle that creates a shock wave when it interacts with the ambient atmosphere or a barrier, and this shock wave naturally impinges on the component surface. This eliminates the need for complex mechanical amplification devices while achieving high cooling effectiveness.
Solution Approach 2:
The invention uses pneumatic principles by utilizing compressed air delivered through a nozzle to create a shock wave. The high-pressure air stream interacts with the ambient atmosphere or a barrier to generate a shock wave that carries the cooling effect to the component surface. This pneumatic approach replaces complex mechanical systems with a simpler gas-dynamics-based solution.
3Area of stationary object
If separate and discrete air nozzles are used for cooling, then cooling coverage is achieved, but manufacturing precision and consistency deteriorate
Solution Approach 1:
The invention merges multiple discrete cooling functions into a single integrated shock wave impingement mechanism. Instead of using separate nozzles positioned at different locations, a single nozzle delivers compressed air that generates a shock wave spreading across the component surface, providing unified and consistent cooling coverage. This consolidation improves manufacturing precision by eliminating the sensitivity to individual nozzle positioning and flow rate variations.
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 cooling device uses less air while achieving more consistent thermal coating results by maintaining desired temperatures and preventing porosity in the coating, regardless of component diameter.
Implementation Method 1
The cooling device includes a manifold that is connected to an air supply. The manifold has a face with multiple impingement holes less than one-eighth inch (3.1 mm) in diameter that are configured to direct cooling air on the component surface.
Implementation Method 2
multiple impingement holes less than one-eighth inch (3.1 mm) in diameter that are configured to direct cooling air on the component surface
Implementation Method 3
Air is supplied at a regulated pressure of about 45 psi (310 kPa), to achieve the desired high air flow rate of about 750 standard cubic feet per hour (scfh) (21 kilo liters per hour).
Data Source
AI summary
This disclosure relates to a thermal spray coating system including a table that is configured to support a component. A spray torch is configured to direct a thermal spray at a component surface. A cooling device is arranged adjacent to spray torch and configured to be in close proximity to the component surface. The cooling device includes a manifold that is connected to an air supply. The manifold has a face with multiple impingement holes less than one-eighth inch (3.1 mm) in diameter that are configured to direct cooling air on the component surface. In one example, the diameter of the impingement holes is approximately 0.059 inch (1.5 mm) and provide cooling air at a velocity of at least 400 ft per second (122 meters per second). The face is arranged within one inch (25 mm) of the component surface, in one example. Accordingly, the above cooling device uses less air and yields more consistent results in thermal coating of the component.