Substrate Material Deposition with Controlled Porosity
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Solution Overview
Problem
Existing material deposition systems face challenges in effectively depositing materials into substrates, particularly in achieving desired porosity and uniform distribution of particles within the substrate, especially in complex geometries like gas turbine engine components.
Innovation Solution
A system and method that utilize an energy emitter to form a melt pool on the substrate in a vertically downward-facing direction, combined with a particle sprayer to direct particles with specific properties into the melt pool, allowing them to rise and integrate with the substrate, forming a matrix material with controlled porosity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional material deposition systems are used, then material can be deposited on substrate surfaces, but the particles cannot be effectively embedded within the substrate to achieve desired porosity and uniform distribution
Solution Approach 1:
The invention utilizes phase transition by directing a high-energy beam (laser, electron beam, or plasma) at the substrate to locally melt or vaporize the material, creating a molten pool. Particles are introduced into this molten pool during the phase transition state, allowing them to be embedded within the substrate. The subsequent solidification of the molten pool traps particles uniformly distributed within the matrix, achieving both uniform particle distribution and controlled porosity that conventional deposition methods cannot accomplish.
2Reliability
If particles are introduced into the substrate, then porosity can be achieved, but uniform distribution and integration with the substrate matrix are difficult
Solution Approach 1:
The invention changes the physical state parameters of the substrate material by using high-energy beams to create localized molten or vaporized regions. By controlling parameters such as beam power, scanning speed, and particle introduction timing, particles are introduced when the substrate is in a molten state with reduced viscosity. This allows particles to be uniformly distributed and naturally integrated into the matrix during solidification, achieving both desired porosity and uniform particle integration without agglomeration or surface-only deposition.
3Manufacturing precision
If high energy beams are used to form melt pools, then particles can be embedded in the substrate, but the system complexity and equipment requirements increase
Solution Approach 1:
The invention employs high-energy beams (laser, electron beam, or plasma) that serve multiple functions: heating and melting the substrate to form a molten pool, vaporizing material to create porosity, and providing the energy necessary for particle embedding. This multi-functionality allows a single energy source to achieve material embedding, porosity control, and uniform particle distribution simultaneously, reducing the need for separate processing steps and equipment while maintaining manufacturing precision.
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
Enables the formation of matrix materials with tailored porosity and composition, enhancing properties such as abradability, lubrication, and thermal conductivity in substrate components like gas turbine engine parts.
Implementation Method 1
directing an energy beam from below a first portion of a substrate upward toward the first portion, forming a melt pool in the substrate using the directed energy beam
Implementation Method 2
at least some of the particles are configured to rise in the melt pool toward the substrate
Data Source
AI summary
One embodiment of the present invention is a unique method for depositing materials in a substrate. Another embodiment is a unique system for depositing materials in a substrate. Other embodiments include apparatuses, systems, devices, hardware, methods, and combinations for depositing materials within a substrate. Further embodiments, forms, features, aspects, benefits, and advantages of the present application will become apparent from the description and figures provided herewith.