Interspacer Masking Structure for Selective Turbine Coating
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Solution Overview
Problem
Existing coating processes for gas turbine components, such as diffusion aluminide coatings, often inadvertently apply to non-target surfaces, leading to unnecessary weight and interference with component coupling, and require laborious removal or scrapping of affected parts.
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 components above projections, thereby allowing selective application of coatings only to desired areas.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a masking device is used to apply coating to gas turbine components, then coating is applied to target surfaces, but coating is also inadvertently applied to non-target surfaces such as root portions
Solution Approach 1:
An interspacer device is introduced as an intermediary element between the masking device and the component root portion. The interspacer includes a lower portion that contacts the root portion and an upper portion with a projecting member that contacts the component above the projection, creating a physical barrier that prevents coating material from reaching non-target surfaces while allowing coating to be applied to target surfaces.
Solution Approach 2:
The interspacer device is segmented into distinct functional portions: a lower portion for contacting the root portion, an upper portion extending above the lower portion, and a projecting member extending beyond the upper portion. This segmentation allows each portion to perform its specific function in preventing unwanted coating while maintaining component accessibility.
2Quantity of substance
If coating is applied to non-target surfaces such as root portions, then complete coverage is achieved, but component weight increases and coupling functionality is interfered with
Solution Approach 1:
The interspacer acts as a mediator that selectively blocks coating material from reaching non-target surfaces like root portions, allowing coating to be applied only where needed. This prevents unnecessary weight addition to critical areas while maintaining coating coverage on target surfaces that require protection.
3Quantity of substance
If coating is applied to non-target surfaces, then complete coverage is achieved, but laborious removal or scrapping of affected parts is required
Solution Approach 1:
By introducing the interspacer as a physical barrier during the coating process, unwanted coating on non-target surfaces is prevented entirely. This eliminates the need for subsequent laborious removal operations or scrapping of affected components, significantly improving manufacturing efficiency and reducing waste.
Solution Approach 2:
The interspacer is positioned in advance before coating application to prevent coating material from contacting non-target surfaces. This preliminary protective action avoids the need for post-coating correction operations, making the manufacturing process more efficient and cost-effective.
4Manufacturing precision
If an interspacer device is introduced to prevent unwanted coating, then coating precision is improved, but device complexity increases
Solution Approach 1:
The interspacer serves as a simple intermediary device that can be integrated into existing masking systems. Its straightforward structure with distinct portions for contacting different component surfaces adds minimal complexity while significantly improving coating precision by preventing material from reaching non-target areas.
Data Source
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.