Laser Sealing of Machined Ceramic Surfaces in Gas Turbine Parts
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Solution Overview
Problem
Ceramic materials used in gas turbine engines face challenges due to their porosity, which can lead to infiltration of substances that may cause undesired reactions and reduce the durability of the components.
Innovation Solution
A method involving machining a closed-pore surface of a silicon-containing gas turbine engine article to produce an open-pore surface, followed by laser-treatment to form an oxide that seals the open-pores, resulting in a closed-pore treated surface.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If machining is performed on closed-pore ceramic surface to produce features, then manufacturing precision and functionality are improved, but porosity increases and durability deteriorates
Solution Approach 1:
The laser treatment is applied immediately after machining while the workpiece is still in position, sealing the open pores before harmful substances can infiltrate. This preliminary sealing action prevents the durability deterioration that would otherwise result from the machining-induced porosity.
Solution Approach 2:
The laser treatment converts the harmful open pores created by machining into beneficial sealed structures. By using laser energy to form an oxide layer, the previously harmful porosity is transformed into a sealed surface that enhances durability while preserving the machined feature geometry.
2Reliability
If laser treatment is applied to seal open-pore surface, then durability and resistance to harmful factors are improved, but additional process steps and complexity are introduced
Solution Approach 1:
The laser treatment process is integrated with the machining operation into a single workflow. The laser sealing is performed in-situ on the machined surface without requiring separate handling or additional setup, thereby combining two operations into one efficient process sequence.
Solution Approach 2:
Traditional mechanical sealing methods (such as coating or plugging) are replaced with laser-based thermal-chemical sealing. The laser induces oxide formation through controlled heating, substituting mechanical intervention with a thermal field approach that is more precise and integrated.
3Reliability
If conventional sealing methods are used after machining, then porosity is reduced, but additional manufacturing steps and time are required
Solution Approach 1:
The laser sealing operation continues immediately after machining without interruption or intermediate steps. The useful action of sealing is performed continuously on the freshly machined surface, eliminating idle time and ensuring that the porous surface is sealed before any harmful infiltration can occur.
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 method effectively seals the open-pores, enhancing the durability and resistance of the ceramic components to environmental factors, thereby extending their lifespan and performance in high-temperature environments.
Implementation Method 1
The open-pore machined surface is then laser-treated to cause formation of an oxide in the silicon-containing gas turbine engine article that seals the open-pore machined surface
Implementation Method 2
laser-treated to cause formation of an oxide in the silicon-containing gas turbine engine article that seals the open-pore machined surface
Data Source
Figure 1~2
Figure 3
AI summary
A method includes machining a closed-pore surface (70) of a silicon-containing gas turbine engine article (60) to produce a feature (68). The machining causes removal of the closed-pore surface (70) to produce an open-pore machined surface (74). The open-pore machined surface (74) is then laser-treated to cause formation of an oxide in the silicon-containing gas turbine engine article (60) that seals the open-pore machined surface (74) to produce a closed-pore treated surface (78).