3D-Printed Sandblasting Masks for Gap-Free Blade Tip Alignment
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Solution Overview
Problem
Conventional sandblasting masks for turbomachine compressor blades are cumbersome, hazardous to handle, and require gap covering operations, posing risks to operators and equipment, with potential damage from handling and unsatisfactory alignment during use.
Innovation Solution
A sandblasting mask system using lightweight, 3D-printed plastic bodies with polyurea-based coatings, designed for precise alignment without gaps, allowing self-supporting assembly and easy handling, and featuring male/female ends for secure fitting, reducing the need for external supports and adhesive tapes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Area of stationary object
If a metal profile mask weighing 2-5 kg and measuring 5 meters is used for sandblasting, then the mask can cover multiple blades, but it becomes dangerous to handle and risks hitting and damaging equipment
Solution Approach 1:
The single large metal mask is divided into multiple smaller individual masks, each weighing only 50-100g. These segmented masks can be handled safely by operators while collectively providing the same coverage area when positioned around multiple blades.
Solution Approach 2:
The material parameter is changed from heavy metal (2-5 kg) to lightweight plastic (50-100g per mask). This parameter change maintains the protective function while eliminating the handling dangers associated with heavy weight.
2Area of stationary object
If a metal profile mask is used, then coverage is provided, but gaps between mask ends require adhesive tape or silicone joint covering
Solution Approach 1:
The mask system is segmented into multiple individual masks that are positioned separately around blades. Each mask is self-contained with no gaps at ends, eliminating the need for adhesive tape or silicone joints to seal gaps.
Solution Approach 2:
The masks are made as inexpensive, disposable plastic components rather than permanent metal structures requiring maintenance and gap sealing. Each mask is simple enough to be replaced rather than repaired.
3Reliability
If a metal profile mask is used, then sandblasting coverage is achieved, but external holding structures are required to keep masks in place
Solution Approach 1:
The mask system is segmented into multiple small masks that are individually positioned and held in place by simple clips or elastic retention mechanisms integrated into each mask, eliminating the need for complex external holding structures.
Solution Approach 2:
Each mask is designed to be self-holding through integrated clips or elastic retention features that automatically secure the mask in position during sandblasting without requiring external support structures.
4Weight of moving object
If plastic material with polyurea coating is used for masks, then weight is reduced and handling is facilitated, but coating durability must be maintained
Solution Approach 1:
The mask uses a composite structure combining lightweight plastic substrate with polyurea coating. This composite provides both the weight reduction benefits of plastic and the durability benefits of polyurea, achieving optimal balance between handling ease and protective function.
Solution Approach 2:
The material parameters are optimized by selecting specific plastic types and polyurea coating thicknesses to achieve the desired weight (50-100g) while maintaining sufficient coating durability for sandblasting applications.
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
Enhances operator and equipment safety, simplifies handling, ensures precise sandblasting without gaps, and maintains mask durability through replaceable coatings, minimizing damage risks and improving operational efficiency.
Implementation Method 1
The coating is particularly resistant to the abrasiveness of sand. The coating thus protects the body of the mask
Implementation Method 2
the bodies of the masks are made of plastic material and produced by 3D printing
Data Source
AI summary
The invention relates to a sandblasting mask (50) as well as its use for the sandblasting of blade tips in a method comprising a step of positioning a plurality of sandblasting masks (50), each blade passing through an opening (58) of a mask and each blade tip extending projecting from the respective mask, the masks being assembled two by two preferably without play; and a step of sandblasting the protruding blade tips of the masks.The masks (50) are preferably produced by plastic additive manufacturing and coated with a polyurea-based coating.