Multi-Axis Tumbler Coating for Turbine Airfoil Uniformity
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Solution Overview
Problem
Existing coating techniques for industrial turbine and jet engine components, such as EB-PVD, are line of sight methods that fail to consistently coat surfaces not in direct line of sight, leading to undesirable coating characteristics like cracking and fracturing, especially on airfoil portions and surfaces perpendicular to them.
Innovation Solution
A modular fixture system that allows workpieces to be simultaneously manipulated about multiple axes while maintaining a fixed horizontal and vertical position relative to the coating material source, rotating about two axes and tilting up to 45 degrees, ensuring uniform coating thickness and minimizing premature spalling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If line of sight coating techniques (such as EB-PVD) are used, then the coating process is simple and direct, but surfaces not in line of sight with the source will not be coated properly, leading to cracking and fracturing
Solution Approach 1:
The workpiece is dynamically manipulated through multi-axis rotation and tilting mechanisms, allowing it to rotate about a first axis while simultaneously tilting about a second axis. This dynamic movement ensures all surfaces including those perpendicular to the airfoil portion receive consistent coating material deposition, eliminating the line-of-sight limitation of static coating systems.
Solution Approach 2:
The invention introduces additional rotational dimensions by manipulating the workpiece about multiple axes simultaneously. The workpiece rotates about a first axis while tilting about a second axis, adding dimensional complexity to the coating process. This multi-dimensional manipulation ensures comprehensive surface coverage that cannot be achieved with single-axis or static positioning systems.
2Adaptability or versatility
If workpieces are not kept at a constant distance from the coating material source, then the coating operation can accommodate varying workpiece positions, but the coatings will exhibit undesirable characteristics such as cracking and fracturing
Solution Approach 1:
The system maintains constant distance through dynamic multi-axis manipulation where the workpiece rotates and tilts while preserving a fixed radial distance from the coating source. This dynamic constraint ensures uniform coating thickness and material deposition rate, preventing the cracking and fracturing associated with variable distance positioning.
Solution Approach 2:
The invention changes the operational parameters by maintaining a constant distance parameter while varying the angular orientation parameters. The workpiece undergoes angular changes through rotation and tilting, but the radial distance parameter remains fixed, ensuring consistent coating quality while achieving comprehensive surface coverage.
3Device complexity
If traditional fixtures are used that do not maintain fixed horizontal and vertical position, then the apparatus is simpler, but the coating is more susceptible to fracture and cracking
Solution Approach 1:
The fixture incorporates dynamic multi-axis manipulation capabilities with rotation about a first axis and tilting about a second axis. This dynamic mechanism maintains the workpiece center at a fixed horizontal and vertical location relative to the coating source while achieving comprehensive surface coverage, significantly improving coating durability compared to simpler static fixtures.
Solution Approach 2:
The fixture serves multiple functions simultaneously: it holds the workpiece, rotates it about a first axis, tilts it about a second axis, and maintains fixed horizontal and vertical positioning. This multi-functionality achieves superior coating reliability while managing the necessary complexity through integrated design.
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 solution achieves a coating that is less susceptible to cracking or fracturing, provides uniform coating thickness, and allows for faster part changeovers, enabling more efficient and consistent coating of multiple workpieces with each cycle.
Implementation Method 1
heating the coating material to form a cloud of coating material
Data Source
AI summary
The present invention relates to an apparatus for coating one or more workpieces such as components to be used in jet engines or industrial turbines. The apparatus comprises a device for simultaneously manipulating a workpiece about multiple axes while holding a center of the workpiece at a fixed position with respect to a source of coating material. The device for manipulating the workpiece preferably comprises a modular fixture while allows the workpiece to be simultaneously rotated about a first axis, rotated about a second axis at an angle to the first axis, and titled through a range of motion such as from +45 degrees to −45 degrees with respect to the first axis.