Modular Turbomachine Coating System for Local Composition Tailoring

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Solution Overview

Problem

Current coating methods for turbomachines are inflexible, time-consuming, and prone to misfit and irregularities between layers, failing to adapt locally varying thermal, chemical, and mechanical stress requirements effectively, leading to suboptimal performance and increased maintenance.

Innovation Solution

A modular composite coating system using separate powder feeders for each base powder, allowing simultaneous thermal spraying with independent control of powder feeding rates to achieve tailored compositions and microstructures, enabling flexible adaptation to specific component needs and reducing coating time and efforts.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If conventional coating methods are used with mixed powder feeders, then coating process is simpler, but coating composition cannot be tailored locally and requires time-consuming layer-by-layer application

Engineering Contradiction:

Improvelocal composition tailoringVSAvoidpowder feeder system

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The coating system segments the powder delivery function by providing separate powder feeders for each base powder instead of using a single mixed powder feeder. This allows independent control and delivery of different powders (e.g., metal powder, ceramic powder, oxidation protection powder) to different locations on the component, enabling local composition tailoring while maintaining process efficiency through simultaneous deposition

Inventive Principle:

Principle #1Segmentation

2Adaptability or versatility

If multiple coating layers are applied sequentially to achieve different properties, then coating composition can be varied, but coating time increases and misfit irregularities occur between layers

Engineering Contradiction:

Improvecoating property variationVSAvoidcoating deposition rate

Core Design Contradiction:

Adaptability or versatilityVSProductivity

Solution Approach 1:

The invention merges multiple coating materials into a single simultaneously deposited composite coating by using separate powder feeders that deliver different base powders at the same time. This eliminates the need for sequential layer application, reducing total coating time and avoiding misfit irregularities between layers while still achieving varied coating properties through controlled powder feeding rates and compositions

Inventive Principle:

Principle #5Merging (Combining)

3Adaptability or versatility

If standard thermal spraying is used with fixed powder composition, then process is simpler, but cannot adapt to locally varying thermal, chemical, and mechanical stress requirements

Engineering Contradiction:

Improvelocal requirement adaptationVSAvoidcoating process complexity

Core Design Contradiction:

Adaptability or versatilityVSEase of manufacture

Solution Approach 1:

The coating system implements local quality by enabling different powder compositions and ratios to be deposited at different locations on the component. Separate powder feeders allow the coating composition to be tailored to local requirements - for example, higher ceramic content in high-temperature zones, enhanced oxidation protection at leading edges, or improved ductility in low-stress areas - while maintaining a relatively simple thermal spraying process

Inventive Principle:

Principle #3Local quality

4Reliability

If composite powders are used to achieve tailored properties, then coating performance is optimized, but powder preparation time and complexity increase

Engineering Contradiction:

Improvecoating performanceVSAvoidpowder preparation time

Core Design Contradiction:

ReliabilityVSLoss of time

Solution Approach 1:

The system implements dynamic powder composition control by using separate powder feeders that can independently adjust the feeding rates of different base powders during the coating process. This allows the coating composition to be dynamically tailored to specific local requirements without requiring pre-prepared composite powders, eliminating time-consuming powder blending operations while maintaining optimized coating performance through real-time composition adjustment

Inventive Principle:

Principle #15Dynamics

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 modular approach provides a flexible and efficient coating system that can be tailored to meet specific local requirements, reducing coating time, minimizing misfit issues, and enhancing the durability and performance of turbomachine components by optimizing thermal, chemical, and mechanical properties.

Implementation Method 1

at least two different base powders are simultaneously sprayed onto a surface of said component by means of thermal spraying

Methodology Applied

Scientific EffectThermal spraying: Plasma Spray

Data Source

PatentEP2781617B1Method for coating a component of a turbomachine and coated component for a turbomachine

Publication Date: 2022.10.26 ANSALDO ENERGIA IP UK LTD

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AI summary

The invention relates to a coating system (30, 31, 32) for a component of a turbomachine, comprising at least two different base powders (30, 31, 32), whereby each of said at least two different base powders (30, 31, 32) has an individual predetermined distribution within said coating system (30, 31, 32), and wherein each of said at least two different base powders (30, 31, 32) is responsible for a specific property of said coating system.