High-Temperature Masking System with Elastomeric Liner
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Solution Overview
Problem
Existing masking systems for gas turbine components undergoing high-temperature processes, such as HVOF coating, face challenges with manual application of high-temperature masking tape, which is costly, time-consuming, and prone to errors, leading to unintended coating of non-target areas.
Innovation Solution
A masking system comprising a high-temperature, additively manufactured housing with elastomeric liners, allowing for secure retention and precise exposure of components during high-temperature processes, thereby ensuring targeted coating without affecting other areas.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If manual application of high-temperature masking tape is used, then masking can be performed, but it is costly, time-consuming, and prone to errors
Solution Approach 1:
The masking system is pre-configured with windows positioned and sized to match the exact coating requirements of the component. The elastomeric material is pre-formed with specific geometries that conform to the component features, eliminating the need for manual measurement and application during the masking process.
Solution Approach 2:
The masking system uses a replica or model of the component geometry to create the elastomeric masking material. This copying approach ensures that the masking windows precisely match the target areas that require coating, eliminating errors associated with manual masking tape application.
2Manufacturing precision
If manual application of high-temperature masking tape is used, then masking can be performed, but it leads to unintended coating of non-target areas
Solution Approach 1:
The masking windows are pre-positioned and pre-sized during the manufacturing of the elastomeric masking system, ensuring that only the exact target areas are exposed for coating. This preliminary configuration eliminates the complexity of manual masking tape application and ensures high coating accuracy.
Solution Approach 2:
The elastomeric masking material is created as a copy or replica of the component geometry, with windows that precisely match the areas requiring coating. This copying approach ensures that the masking system automatically achieves high manufacturing precision without complex manual application procedures.
3Temperature
If a rigid masking structure is used, then high-temperature resistance is achieved, but adaptability to components with minor design variations is reduced
Solution Approach 1:
The masking system uses elastomeric material that can change its physical parameters (flexibility, conformability) while maintaining high-temperature resistance. This allows the rigid housing structure to accommodate components with minor design variations through the flexible elastomeric sealing and masking surfaces.
Solution Approach 2:
The masking system combines high-temperature resistant materials with elastomeric materials to create a composite structure. The rigid housing provides high-temperature resistance while the elastomeric components provide adaptability to component variations, achieving both requirements simultaneously.
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 masking system effectively prevents unintended coating, reduces operational time and costs, and ensures consistent, precise application across multiple gas turbine components, even with minor variations in design.
Implementation Method 1
The liner has a back side configured to fit within the first receiving area and a front side having a retaining feature configured to receive and retain the component
Implementation Method 2
a housing made of high-temperature material. The housing has a first shell and a second shell
Data Source
Figure 1
Figure 2
Figure 3~4
AI summary
A masking system for selectively masking a component includes a housing made of high-temperature material. The housing has a first shell and a second shell. The first shell has a first receiving area and a first window that extends through the first shell. The masking system has a liner that includes elastomeric material. The liner has a back side configured to fit within the first receiving area and a front side having a retaining feature configured to receive and retain the component. When the liner is disposed within the first receiving area and the component is received by the retaining feature, the first window corresponds to at least one portion of the component that is accessible.