Micro-channel Coating Deposition via Pressurized Masking
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Solution Overview
Problem
Current micro-channel coating deposition techniques for gas turbine engines face challenges such as the use of sacrificial fillers, which can damage components during removal, and angular deposition methods that allow unwanted coating particles to enter micro-channels, resulting in non-uniform heat transfer and low heat transfer rates.
Innovation Solution
A pressurized masking system that uses a pressure masker and a part coater to project a coating material into grooves on a target surface, with a pressurized masking fluid preventing the coating material from altering the cross-sectional area of coolant supply holes and allowing the coating to bridge grooves to form micro-channels, thereby creating surface cooling channels without damaging the component.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If sacrificial fillers are used to prevent coating deposition in microchannels, then coating can be deposited on the surface, but the fillers must be removed through damaging processes of leaching, etching, or vaporization that require long times
Solution Approach 1:
The patent extracts the harmful sacrificial filler material from the process entirely, replacing it with a pressure masker system that prevents coating deposition without requiring removal. The pressure masker is applied, the coating is deposited, and then the pressure masker is removed - eliminating the need for time-consuming leaching, etching, or vaporization processes.
Solution Approach 2:
The pressure masker acts as an intermediary substance that temporarily blocks the microchannels during coating deposition. It serves the same protective function as sacrificial fillers but can be removed much more easily after the coating process, eliminating the need for damaging removal processes.
2Manufacturing precision
If angular deposition techniques are used to coat microchannels, then coating can be deposited, but unwanted coating particles are deposited into the micro-channels or channel openings
Solution Approach 1:
The pressure masker is applied to the microchannels before the coating deposition process begins. This preliminary action prevents unwanted coating particles from entering the microchannels during deposition, as the pressure masker blocks the channels and prevents particle infiltration.
3Manufacturing precision
If re-entrant grooves are fabricated to form microchannels, then coating particles form a bridge with little or no deposition inside the groove, but the groove opening at the surface must be small enough which complicates the fabrication process
Solution Approach 1:
The patent extracts the complex re-entrant groove fabrication process and replaces it with a simpler approach using standard machining or additive manufacturing to create simple channels or grooves, followed by the application of the pressure masker system that eliminates the need for precise groove geometry.
4Strength
If thin metal walls of high strength superalloy metals are used, then enhanced durability is achieved while minimizing the need for cooling, but the components still require cooling when operating at temperatures above metal part melting temperatures
Solution Approach 1:
The patent segments the cooling system into microchannels that are integrated directly into the component structure. These microchannels provide localized cooling at the heat zone, allowing the component to operate at higher temperatures while maintaining structural integrity through the thin metal walls of high strength superalloy metals.
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
This method effectively forms micro-channels with improved heat transfer rates and uniform temperature profiles by preventing coating material from entering coolant supply holes and ensuring efficient cooling of hot gas path components in gas turbine engines.
Implementation Method 1
passing the pressurized masking fluid at a first pressure through the one or more coolant supply holes and the one or more grooves
Implementation Method 2
allow the coating material to bridge the one or more grooves along a length of the one or more grooves toward an exit region and form the one or more micro-channels
Implementation Method 3
The pressurized masking fluid is forced to flow down the length of the one or more grooves as the one or more grooves are bridged over by the coating material
Implementation Method 4
the cooling fluid may flow through the passages, cooling the hot gas path component substrate and coatings
Implementation Method 5
cooling the hot gas path component substrate and coatings
Data Source
AI summary
Methods of pressure coating a target surface of an article comprising one or more grooves formed in an outer surface of an article include fluidly connecting a pressure masker comprising a pressurized masking fluid to one or more coolant supply holes on a first side of the article. The one or more coolant supply holes in fluidic communication with the one or more grooves. Passing the pressurized masking fluid through the one or more grooves from the first side to a second side comprising the target surface at a pressure less than the coating pressure of the coating material, and, coating the target surface with the coating material to allow the coating material to bridge over the one or more grooves and form one or more micro-channels. The pressurized masking fluid passing through the one or more grooves prevents the coating material from permanently altering a cross sectional area of the one or more grooves along its length.