Solid Lubricant Coating for Gas Turbine Wear Resistance

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Solution Overview

Problem

Components in gas turbine engines, such as gears and bearings, experience high friction, contact temperature increases, surface deterioration, excessive wear, micro pitting, and crack formation due to high stress, which existing coatings fail to adequately address under conditions of high stress and starved lubrication.

Innovation Solution

A solid lubricant wear-resistant coating with a negative thermal expansion coefficient material is applied, combined with oleophilic and oleophobic coatings to regulate contact stress, retain and release lubricant efficiently, and conserve lubricant consumption, respectively.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If existing coatings are applied to gear surfaces, then surface protection is provided, but wear resistance and lubrication efficiency deteriorate under high stress and starved lubrication conditions

Engineering Contradiction:

Improvewear resistanceVSAvoidfriction and surface deterioration

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The coating incorporates a porous structure with controlled pore sizes that can absorb and retain lubricant, providing a reservoir effect. This porous morphology allows the coating to maintain lubrication under starved lubrication conditions while resisting wear and high stress, directly addressing the contradiction between protection and lubrication efficiency

Inventive Principle:

Principle #31Porous materials

Solution Approach 2:

The coating is formulated as a composite material combining multiple phases including solid lubricants, binder materials, and functional additives. This composite structure enables simultaneous achievement of wear resistance, lubrication retention, and stress resistance, resolving the contradiction between surface protection and lubrication efficiency under extreme conditions

Inventive Principle:

Principle #40Composite materials

2Object-affected harmful factors

If lubricant is increased to reduce friction, then lubrication efficiency improves, but lubricant consumption and particle contamination increase

Engineering Contradiction:

ImprovefrictionVSAvoidlubricant consumption

Core Design Contradiction:

Object-affected harmful factorsVSLoss of substance

Solution Approach 1:

The coating system provides self-lubrication through its inherent solid lubricant phases and porous structure that retains lubricant. This self-service mechanism reduces dependence on external lubricant supply, maintaining low friction while minimizing lubricant consumption and the associated particle contamination from lubricant degradation

Inventive Principle:

Principle #25Self-service

Solution Approach 2:

The porous coating structure acts as a lubricant reservoir, absorbing and holding lubricant locally at the contact surface. This localized retention reduces the need for continuous lubricant supply, thereby decreasing overall lubricant consumption while maintaining effective lubrication and reducing friction

Inventive Principle:

Principle #31Porous materials

3Reliability

If coating thickness is increased to improve wear resistance, then durability improves, but contact stress distribution and lubrication efficiency deteriorate

Engineering Contradiction:

ImprovedurabilityVSAvoidcontact stress

Core Design Contradiction:

ReliabilityVSStress or pressure

Solution Approach 1:

The coating utilizes controlled porosity as a key parameter to achieve optimal performance. The porous structure provides mechanical compliance that helps distribute contact stress evenly, preventing stress concentration while maintaining adequate thickness for wear resistance. This parameter optimization resolves the contradiction between durability and stress distribution

Inventive Principle:

Principle #35Parameter changes

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 solution provides enhanced durability and performance by maintaining lubrication efficiency under high stress and temperature conditions, reducing wear and improving resistance to particle presence in lubrication sumps.

Implementation Method 1

the solid lubricant wear resistant coating includes a solid lubricant phase with a negative thermal expansion coefficient material dispersed therein

Methodology Applied

Scientific EffectNegative thermal expansion: Negative Thermal Expansion

Implementation Method 2

oleophilic and oleophobic coatings to regulate contact stress, retain and release lubricant efficiently

Methodology Applied

Scientific EffectCapillary action: Capillary Action

Implementation Method 3

solid lubricant wear resistant coating includes a solid lubricant phase with a negative thermal expansion coefficient material dispersed therein

Methodology Applied

Scientific EffectSolid lubrication: Lubrication

Data Source

PatentEP4421154A1Coatings and coated component

Publication Date: 2024.08.28 GENERAL ELECTRIC CO

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AI summary

A coated component includes a component having a surface, and a solid lubricant wear resistant coating on the surface, wherein the solid lubricant wear resistant coating includes a solid lubricant phase with a negative thermal expansion coefficient material dispersed therein. The component may also include a coating having oleophilic or porous properties disposed on portions thereof, and a coating having oleophobic properties disposed on portions thereof.