Modular Masking Inserts for Gas Turbine Media Blasting
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Solution Overview
Problem
Conventional rigid masking systems for media blasting processes, such as shot peening in gas turbine components, are laborious, time-consuming, and unsuitable for components with small features or minor variations, leading to potential damage and inefficiency in masking different components within the same set.
Innovation Solution
A masking system comprising a universal mask carrier with interchangeable inserts, utilizing toolless connectors and additively manufactured components, allows for flexible and efficient masking of gas turbine components by removably attaching to different insert sections, ensuring uniform masking despite minor variations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional rigid masking systems are used, then masking can be performed, but the process becomes laborious and time-consuming
Solution Approach 1:
The masking system is divided into separate modular components: a mask carrier and interchangeable inserts. Each insert is designed to fit specific component geometries, allowing rapid switching between different masking configurations without重新 fabricating entire masks. This segmentation enables quick adaptation to different gas turbine components while maintaining consistent masking quality.
Solution Approach 2:
The system transitions from static rigid masks to a dynamic interchangeable insert system. The mask carrier can be quickly reconfigured by swapping inserts based on the specific component being masked. This dynamic reconfigurability significantly reduces the time required to prepare masking systems for different components while maintaining the rigidity needed for effective media blasting protection.
2Adaptability or versatility
If conventional rigid masking systems are used, then masking can be performed, but they are unsuitable for components with small features or minor variations
Solution Approach 1:
By segmenting the masking system into a universal carrier and specialized inserts, the design enables precise customization for components with small features. Each insert can be engineered with specific geometric details that match the unique requirements of different gas turbine components, ensuring accurate masking even for intricate features while maintaining the benefit of standardized carrier architecture.
Solution Approach 2:
The inserts are designed with locally optimized features that match specific component geometries. Each insert variation provides tailored masking patterns suited to particular component regions, allowing high-precision masking for small features while the overall carrier structure remains standardized. This local customization approach enables the system to handle minor variations between components effectively.
3Reliability
If conventional rigid masking systems are used, then masking can be performed, but they cause potential damage and inefficiency
Solution Approach 1:
The modular insert design allows for optimized masking geometries that precisely match component features, reducing the risk of media blasting damage to unintended areas. The precision engineering of each insert ensures proper fit and positioning, thereby enhancing masking reliability and preventing harmful effects on the component surfaces that require protection.
Data Source
AI summary
A masking system for selectively masking a component includes a mask carrier having a first carrier section and a second carrier section. The masking system has an insert configured to retain the component. The insert has a first insert section and a second insert section. The first insert section and the first carrier section have a first connector set. The first insert section and the second insert section have a second connector set. The first connector set extends in a first direction and removably couples the first insert section to the first carrier section. The second connector set extends in a second direction oblique to the first direction and removably couples the first insert section to the second insert section.