Internal Aluminization of Cooling Passages Without Complex Masking
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Solution Overview
Problem
The existing manufacturing process for gas turbine engine components with ceramic coatings is complex, challenging, and expensive due to the need for multiple coating steps, including aluminization, which complicates masking and increases costs.
Innovation Solution
A method involving the application of a slurry aluminide to the outlet passageways of cooling systems in gas turbine components, followed by heating with an external gas flow comprising Ar, He, and H2, and subsequent aluminization, which enriches the aluminum content in these areas to enhance oxidation resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If multiple coating steps are used to protect different areas of turbine blades, then adequate protection is achieved, but manufacturing complexity and cost increase
Solution Approach 1:
The patent combines multiple coating operations into a single aluminization process. By applying aluminizing slurry to internal cooling passageways and heating the component, the aluminum diffusion process simultaneously protects multiple surfaces that would otherwise require separate coating steps, thereby reducing manufacturing complexity while maintaining adequate protection.
Solution Approach 2:
The aluminization process serves multiple functions: it protects internal cooling passageways from oxidation, creates a barrier layer on the substrate, and can be applied to various surface geometries including complex internal passages. This multi-functional approach eliminates the need for multiple specialized coating steps for different protection requirements.
2Reliability
If multiple coating steps are used to protect different areas of turbine blades, then adequate protection is achieved, but manufacturing cost increases
Solution Approach 1:
The patent combines multiple coating operations into a single aluminization process. By applying aluminizing slurry to internal cooling passageways and heating the component, the aluminum diffusion process simultaneously protects multiple surfaces that would otherwise require separate coating steps, thereby reducing manufacturing complexity while maintaining adequate protection.
3Manufacturing precision
If masking is applied to protect exterior surfaces during aluminization, then surface degradation is prevented, but process complexity increases
Solution Approach 1:
The patent extracts the masking step from the aluminization process by introducing a suction-based slurry delivery system. The slurry is delivered directly through the cooling passageways using suction, eliminating the need for external masking to prevent slurry deposition on exterior surfaces. This maintains surface quality while reducing process complexity.
Solution Approach 2:
The patent uses an intermediary suction-based delivery system to transport aluminizing slurry into the cooling passageways. This intermediary mechanism replaces the need for physical masking, allowing controlled slurry delivery to internal surfaces while preventing exterior contamination through the suction-driven flow path.
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 simplifies the coating process, reduces the need for masking, and enhances the oxidation resistance of internal cooling passageways by enriching the aluminum content, thereby improving the durability of the components.
Implementation Method 1
heating the component to aluminize the cooling passageway system
Implementation Method 2
enriches the aluminum content in these areas
Implementation Method 3
the suction source drawing the external gas in through the outlet passageways and out through the one or more inlet ports
Data Source
AI summary
A method for coating a component having: a metallic substrate; a ceramic coating having one or more ceramic coating layers atop the substrate; and a cooling passageway system comprising a plurality of feed passageways extending from one or more inlet ports and a plurality of outlet passageways. The outlet passageways have openings in the coating. The method involves: applying a slurry aluminide to the plurality of outlet passageways; coupling the one or more inlets to a suction source; applying an external gas flow to the component, the suction source drawing the external gas in through the outlet passageways and out through the one or more inlet ports, the external gas flow comprising at least 50% by volume combined one to all of Ar, He, and H2; and while the suction source is drawing the external gas, heating the component to aluminize the cooling passageway system.