Rotor Sector Coating Tool for Low-Angle Ceramic Seal Deposition
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Solution Overview
Problem
The existing methods for coating wipers in turbojet engines with ceramic material face challenges due to the geometry of the rotors and blades, limiting the spraying angle and resulting in poor adhesion and wear resistance, with the formation of porosities impairing cohesion and requiring subsequent machining to prevent porosity formation.
Innovation Solution
A tool and method that position a torch and machining tool relative to the rotor sector, allowing simultaneous projection of ceramic material and machining, with the machining tool eroding the coating to prevent porosity formation and ensuring precise coating application directly on the wipers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the rotor geometry with blades is used, then the sealing function is achieved, but the projection angle for coating is limited to very low angles (around 10°)
Solution Approach 1:
The coating process is divided into two distinct sequential operations: first machining the wiper surface to prepare it, then projecting the ceramic coating material. This segmentation allows each operation to be optimized independently, with machining creating a receptive surface and coating applied at optimal angles for adhesion.
Solution Approach 2:
The wiper surface is machined before the coating is projected onto it. This preliminary machining action prepares the surface by removing imperfections and creating a texture that will enhance subsequent coating adhesion, allowing the coating to be applied at better angles than would be possible on the as-manufactured surface.
2Ease of manufacture
If low projection angle (around 10°) is used for coating, then the coating can be applied to the wipers, but the adhesion is very low and porosities form
Solution Approach 1:
The wiper surface is machined before coating application to create a surface that enhances adhesion. This preliminary surface preparation allows subsequent coating to achieve better bonding even when projection angles are constrained by the rotor geometry.
Solution Approach 2:
The surface characteristics of the wiper are changed through machining before coating. By modifying the surface topology and removing imperfections, the adhesion parameters are improved, allowing the ceramic coating to bond more effectively despite the limited projection angles imposed by the rotor blade geometry.
3Ease of manufacture
If low projection angle is used, then coating can be deposited, but porosities in chimneys form that impair cohesion
Solution Approach 1:
The wiper surface is machined before coating deposition to remove surface imperfections that would trap porosity. This preliminary action creates a cleaner, more uniform surface that reduces the formation of chimney porosities during coating deposition, improving overall coating cohesion.
Solution Approach 2:
The surface parameters of the wiper are modified through machining to reduce porosity formation. By changing the surface topology and removing defects, the conditions for coating deposition are improved, reducing the formation of harmful porosities and enhancing coating cohesion.
4Ease of manufacture
If conventional coating method is used, then ceramic material can be projected, but wear resistance is insufficient
Solution Approach 1:
The wiper surface is machined before ceramic coating application to create a surface that enhances bonding. This preliminary surface preparation significantly improves the adhesion of the ceramic coating, which directly translates to enhanced wear resistance while maintaining the ease of ceramic material projection.
Solution Approach 2:
The surface parameters of the wiper are changed through machining to optimize coating adhesion and wear resistance. By modifying the surface characteristics before ceramic deposition, the resulting coating provides superior wear resistance compared to conventional direct coating methods.
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 enhances adhesion and wear resistance by preventing porosity formation and allowing for direct, precise coating application, reducing the need for subsequent machining and improving the sealing performance of labyrinth seals.
Implementation Method 1
a torch, adapted to project a ceramic material
Implementation Method 2
the torch and the machining tool are positioned on either side of the centering arm... actuates the torch so as to project a ceramic material onto the wipers
Implementation Method 3
the machining tool being positioned so as to machine said wipers in parallel with the projection of ceramic material by the torch
Data Source
Figure 1~2
Figure 3~4
Figure 5
AI summary
Tooling for coating blades (2) of a rotor sector (1) of a turbomachine, comprising a support (3) for a rotor sector (1), a centering plate (4) adapted to be inserted into a rotor sector (1), said centering plate (4) having a central housing (41), a tool (5), said tool (5) comprising a centering arm (6), adapted to be inserted into the central housing (41) of the centering plate (4), a torch (7), adapted for projecting a ceramic material, a machining tool (8), said tooling being configured so as to position the tool (5) relative to the rotor sector (1) via the centering plate (4), and to simultaneously perform on the rotor sector (1) a projection of ceramic material and a machining on two separate sectors of the blades (2).