Porous Aluminum Coating Corrosion Protection via Ormosil Infiltration
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Solution Overview
Problem
Porous aluminum coatings used in applications like gas turbine engines are prone to internal corrosion due to their porosity, which weakens the coating and leads to fatigue cracking and spallation, as evidenced by white corrosion products and surface swelling/lifting.
Innovation Solution
An ormosil suspension containing tetraethylorthosilicate, vinyltrimethoxysilane, 3-(trimethoxysilyl) propylmethacrylate, and hexyltrimethoxysilane is infiltrated into the porous aluminum coating, followed by drying to form a solid film, enhancing corrosion resistance and mechanical properties while preserving abradability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If porous aluminum coating is applied to provide abradability, then ease of operation is improved, but corrosion resistance deteriorates due to porosity allowing water penetration
Solution Approach 1:
The patent uses a porous aluminum coating structure that maintains abradability while incorporating hydrophobic treatment to prevent corrosion through the pores
Solution Approach 2:
The patent creates a composite structure by combining porous aluminum coating with hydrophobic ormosil suspension treatment, achieving both abradability and corrosion resistance
2Reliability
If corrosion protection layer is added to improve corrosion resistance, then reliability is improved, but coating complexity increases
Solution Approach 1:
The patent combines corrosion protection and abradability requirements into a single integrated coating system, eliminating the need for separate layers
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 method effectively reduces water wicking and improves durability by forming a hydrophobic solid film with a thickness of 2.0 to 15 microns, providing enhanced corrosion resistance and mechanical stability to the aluminum surfaces.
Implementation Method 1
infiltrating the porous aluminum coating with the ormosil suspension
Implementation Method 2
an ormosil suspension which can be used to protect against corrosion in a porous aluminum coating
Implementation Method 3
forming a hydrophobic solid film with a thickness of 2.0 to 15 microns, providing enhanced corrosion resistance
Data Source
AI summary
A method for protecting porous aluminum coatings includes the steps of: providing an orsomil suspension; and infiltrating the porous aluminum coating with said orsomil suspension. The porous aluminum coating may be thermally sprayed coating.