Interspacer Geometry for Selective Coating Gap Masking
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Solution Overview
Problem
Existing gas turbine components face challenges in selectively applying coatings, such as diffusion aluminide coatings, to specific areas while avoiding unintended application on non-target surfaces, which can lead to unnecessary weight and interference with component coupling.
Innovation Solution
The use of an interspacer device that fills the gap between components within a masking system, ensuring consistent spacing and preventing coating on non-target surfaces by contacting the component above projections, thereby facilitating selective coating of only the intended areas.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional masking methods are used without interspacers, then the masking device structure is simpler, but coating is inadvertently applied to non-target surfaces including component projections and gaps between components
Solution Approach 1:
The patent introduces interspacers as intermediary elements between the masking device and component projections. These interspacers fill gaps and prevent coating material from reaching non-target surfaces, thereby improving coating precision without fundamentally redesigning the masking device structure
Solution Approach 2:
The masking system is segmented into multiple functional components: the masking device, interspacers, and support structures. This segmentation allows each component to perform its specific function independently, with interspacers specifically addressing the gap-filling and projection-shielding functions
2Productivity
If coating is applied to non-target surfaces, then the coating process is simpler and faster, but unnecessary weight is added and component coupling is interfered with
Solution Approach 1:
The interspacers are positioned in advance to prevent coating material from reaching non-target surfaces. This preliminary protective action avoids the need for subsequent coating removal and prevents unwanted weight addition, maintaining coating process efficiency while protecting component integrity
3Productivity
If coating is inadvertently applied to projections and non-target areas, then the coating process is faster, but laborious removal of excess coating is required
Solution Approach 1:
The interspacers are installed before the coating process to pre-establish protective barriers. This preliminary action prevents coating material from adhering to non-target surfaces in the first place, eliminating the need for subsequent coating removal operations and associated time losses
4Device complexity
If the masking device does not account for component projections, then the masking device design is simpler, but consistent spacing and selective shielding cannot be achieved
Solution Approach 1:
The interspacers provide localized protection specifically at gap regions and projection areas where coating precision is critical. This local quality enhancement allows the rest of the masking device to remain relatively simple while achieving precise spacing and selective shielding where needed
Data Source
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Figure 3A
AI summary
An interspacer is configured to be disposed in an area of a device. The area has a height. The interspacer includes a lower portion having a first end and a second end. The interspacer includes an upper portion extending above the lower portion and having a projecting member. The projecting member extends beyond the second end away from the first end. A height of the interspacer is equal to the height of the area.