Rotatable Barrel Fixture for Combustor Panel Coating Throughput
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Solution Overview
Problem
Existing metallic coating processes for combustor panels are time-consuming and result in low throughput, leading to premature burn through and expensive replacement procedures.
Innovation Solution
A method and apparatus utilizing a rotatable mounting fixture to coat combustor panels in a barrel configuration, allowing for simultaneous cleaning, preheating, and coating of multiple panels, thereby increasing throughput and improving adhesion of ceramic top coats.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If traditional coating procedures are used, then coating quality is maintained, but throughput is low and processing time is long
Solution Approach 1:
The support structure is divided into multiple holders arranged in a circular pattern, with each holder capable of independently supporting a combustor panel. This segmentation allows multiple panels to be coated simultaneously in parallel, transforming a single-panel sequential process into a multi-panel parallel process, thereby dramatically increasing throughput while maintaining coating quality
Solution Approach 2:
The invention transitions from a linear or static support arrangement to a circular rotational configuration. The rotatable support structure enables panels to be arranged in a circular dimension, allowing the coating system to process multiple panels at different angular positions simultaneously. This dimensional change from linear to circular arrangement maximizes space utilization and enables continuous processing
2Productivity
If multiple panels are coated simultaneously, then throughput increases, but coating consistency and quality control become more difficult
Solution Approach 1:
The support structure incorporates rotational capability, allowing the entire array of held panels to rotate during the coating process. This dynamic rotation ensures that all panels receive uniform exposure to the coating material regardless of their initial angular position, maintaining consistent coating quality across all panels while enabling simultaneous processing of multiple components
Solution Approach 2:
The rotatable support structure serves multiple functions: it holds multiple panels simultaneously, rotates to ensure uniform coating distribution, and can be adjusted to accommodate different panel configurations. This multi-functionality allows the same apparatus to maintain coating consistency across varying production scenarios while sustaining high throughput
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 achieves a fourfold increase in coating throughput, reduces machine downtime, and enhances consistency in coating coverage and surface roughness, leading to improved service life of combustor panels.
Implementation Method 1
exposing the fixture and the component to a reverse transfer arc (RTA) cleaning/pre-heating procedure
Implementation Method 2
a coating is directed at the component in a direction perpendicular to the axis of the rotatable member
Data Source
AI summary
A method of coating a component includes attaching the component to a support that is configured to hold a plurality of components and placing a base of the support in a holder that is attached to rotatable member of a fixture, wherein an axis of the holder is parallel to an axis of rotation of the rotatable member. The method also includes transporting the fixture into a coating chamber wherein a direction of an exit stream of a coater in oriented perpendicularly to the axis of rotation, exposing the fixture and the component to a reverse transfer arc cleaning/pre-heating procedure, and exposing the fixture and the component to a coating procedure during which a coating is directed at the component in a direction perpendicular to the axis of rotation while the rotatable member is rotating. The method further includes transporting the fixture and removing the component from the support fixture.