Rotor Abrasion Coating via Electrostatic Thermal Spraying
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Solution Overview
Problem
Conventional methods for applying abrasion-resistant materials to rotors, such as electroplating and electroforming, are slow, complex, and require significant post-process upgrades, as well as incurring high handling and shipping costs due to the need for transporting rotors to facilities, resulting in inefficiencies and increased costs.
Innovation Solution
A process involving thermal spraying of a mixed composition comprising an elastomeric and metallic material onto the rotor, with multiple coats transitioning from elastomeric to metallic-rich compositions, allowing for in-field application using manual or automated processes, reducing the need for extensive processing and handling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If electroplating or electroforming is used to apply abrasion resistant material, then wear resistance is improved, but handling and shipping costs increase due to rotor transport to facilities
Solution Approach 1:
The rotor applies the abrasion resistant coating to itself through electrostatic charging. The rotor is charged to a potential different from the coating material, causing the coating to be attracted and deposited onto the rotor surface without requiring external plating facilities or rotor transport.
2Reliability
If electroplating is used to apply abrasion resistant material, then wear resistance is improved, but post-process upgrade work increases due to non-uniform coating thickness
Solution Approach 1:
The rotor and coating material are maintained at different electrostatic potentials, creating a uniform electric field that attracts coating particles evenly across the rotor surface. This results in uniform coating thickness that eliminates the need for post-process grinding or machining.
3Reliability
If conventional coating methods are used, then wear resistance is improved, but device complexity increases due to requirement of plating facilities
Solution Approach 1:
The rotor system performs the coating operation itself through electrostatic charging, eliminating the need for external plating facilities, equipment, and infrastructure. The entire coating process can be performed in-field without complex industrial equipment.
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
This approach reduces handling and shipping costs, minimizes post-process upgrades, and enables efficient application of abrasion-resistant materials directly on the rotor, enhancing wear resistance while allowing for on-site processing, thus improving the efficiency and cost-effectiveness of the process.
Implementation Method 1
A process for thermally spraying a mixed composition comprising an elastomeric and a metallic material onto a rotor
Implementation Method 2
The rotor is charged to a potential different from that of the coating material
Data Source
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AI summary
A process for applying a plurality of coats of abrasion resistant material to a substrate such as a rotor for an aircraft. The abrasion resistant material is composed of a first and a second material. The coats gradually transition from an abrasion resistant composition having a larger percentage part per volume of the first material to a larger percentage part per volume of the second material as additional coats are applied.