Lined Cooling Aperture Formation for Turbine Coating Integrity
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Solution Overview
Problem
Existing methods for forming cooling apertures in gas turbine engine components are not fully optimized, lacking in efficiency and precision, which can affect the performance and durability of fluid-cooled components.
Innovation Solution
A manufacturing method involving a preform component with a substrate, where internal and external coatings are applied to form meter and diffuser sections of cooling apertures, using different machining processes for each section and specific coating materials like aluminide and ceramic, to create a fully formed cooling aperture without further machining.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional cooling aperture formation methods are used, then the basic cooling function is achieved, but the manufacturing precision and efficiency are not optimized
Solution Approach 1:
The cooling aperture formation process is segmented into distinct stages: preform meter section formation, internal coating application, preform diffuser section formation, and external coating application. Each segment is optimized independently, allowing precise control of aperture geometry while maintaining manufacturing efficiency through specialized processes for each stage.
Solution Approach 2:
The meter section of the cooling aperture is formed in advance during the preform manufacturing stage, before final component production. This preliminary action allows precise aperture geometry to be established early, reducing subsequent machining requirements and improving overall manufacturing precision and efficiency.
2Manufacturing precision
If multiple machining processes are used for different sections, then the manufacturing precision is improved, but the device complexity increases
Solution Approach 1:
Different machining processes are applied to different sections of the cooling aperture based on their specific quality requirements. The meter section uses one machining process optimized for precision, while the diffuser section uses another process optimized for its geometric requirements. This local quality approach ensures each section achieves its target precision without requiring all sections to undergo every possible machining operation.
Solution Approach 2:
The aperture formation process is divided into separate operational stages with different machining methods for meter and diffuser sections. This segmentation allows each section to be processed by the most appropriate technique, reducing overall process complexity compared to using a single universal machining approach for the entire aperture.
3Reliability
If external coating is applied over the substrate, then the durability is enhanced, but the risk of coating damage during machining increases
Solution Approach 1:
The meter section is formed and coated internally before the external coating is applied to the diffuser section. This preliminary action sequence ensures that critical aperture sections are protected with internal coating before external coating is applied, reducing the risk of damage to protective coatings during subsequent machining operations.
Solution Approach 2:
Instead of applying external coating first and then machining, the process inverts the sequence by forming and internally coating the meter section first, then applying external coating to the diffuser section. This inversion protects the most critical sections from coating damage during machining, enhancing durability while minimizing harmful effects.
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 ensures precise formation of cooling apertures that meet design specifications, enhancing the performance and durability of fluid-cooled components by reducing the risk of damage to external coatings and potential material degradation.
Implementation Method 1
An internal coating is applied to the preform aperture to line the preform aperture and provide a meter section of the cooling aperture
Implementation Method 2
An internal coating is applied to the preform aperture to line the preform aperture and provide a meter section of the cooling aperture
Implementation Method 3
External coating material is applied over the substrate. The applying of the external coating material forms an external coating over the substrate. The applying of the external coating material also builds up the external coating material within the preform diffuser section to form a diffuser section of the cooling aperture
Implementation Method 4
External coating material is applied over the substrate. The applying of the external coating material forms an external coating over the substrate
Data Source
AI summary
A manufacturing method is provided. During this method, a preform component is provided for a turbine engine. The preform component includes a substrate. A preform meter section and a preform diffuser section are formed in the substrate. An internal coating is applied to at least the preform meter section to provide a meter section of a cooling aperture. External coating material is applied over the substrate. The applying of the external coating material forms an external coating over the substrate. The applying of the external coating also builds up the external coating material within the preform diffuser section to form a diffuser section of the cooling aperture.