Thermal Coating of Component Stacks with Variable Beam Angles
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Solution Overview
Problem
Existing thermal coating methods for component stacks with non-uniform or convex geometries fail to produce a smooth and continuous coating with even layer thicknesses due to fixed angles between the coating beam and the inner bounding surface, which are too flat in certain regions.
Innovation Solution
A method involving two coating passes with different angles, where the first angle is formed during the first pass and the second angle, opposite to the first, is formed during the second pass, allowing the coating beam to be incident approximately perpendicular to all surface elements, using a rotating thermal spray apparatus or rotating the component stack to achieve uniform coating.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a fixed angle coating method is used, then the coating process is simple and fast, but the layer thickness becomes uneven on components with non-uniform or convex geometries
Solution Approach 1:
The patent applies the dynamics principle by making the coating beam angle adjustable during the coating process. Instead of using a fixed angle, the coating beam's angle of incidence can be dynamically changed to adapt to different surface geometries. This allows the coating process to maintain both speed and precision by optimizing the angle for each specific surface region being coated.
Solution Approach 2:
The patent implements parameter changes by varying the angle of the coating beam during the coating process. The angle parameter is changed from a fixed value to a variable that can be adjusted based on the surface geometry. This parameter change enables the coating system to accommodate non-uniform and convex geometries while maintaining consistent layer thickness.
2Manufacturing precision
If the coating beam angle is adjusted for non-uniform geometries, then layer thickness uniformity improves, but the coating process complexity increases
Solution Approach 1:
The patent applies universality by designing a coating apparatus that can perform multiple functions: it can coat both simple and complex geometries using a single adjustable-angle coating beam system. This multi-functional capability eliminates the need for multiple specialized coating devices, reducing overall system complexity while maintaining precision.
Solution Approach 2:
The patent introduces an additional degree of freedom by allowing the coating beam to move or rotate, changing its angle of incidence. This dimensional change adds the capability to coat complex geometries without requiring multiple fixed-angle coating heads, thereby improving precision without proportionally increasing device complexity.
3Productivity
If a single coating pass is used, then the coating process is efficient, but smooth and continuous layer extent cannot be achieved on convex geometries
Solution Approach 1:
The patent applies periodic action by using multiple coating passes with different beam angles. The coating process is divided into sequential passes, each targeting specific regions of the component. This periodic approach ensures that convex and non-uniform geometries receive proper coating angles during different passes, achieving smooth and continuous layers while maintaining reasonable efficiency.
Solution Approach 2:
The patent implements preliminary action by performing a first coating pass to establish a base layer, followed by additional passes to refine and smooth the coating on complex geometries. This preliminary coating followed by refinement ensures that even difficult-to-reach areas receive adequate coverage, achieving surface smoothness without completely sacrificing efficiency.
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 coating of components with non-uniform inner cross-sections to achieve a smooth and continuous layer extent with even layer thicknesses, effectively addressing the limitations of fixed-angle coating methods.
Implementation Method 1
During the coating process an inner bounding surface of the component opening is thermally coated from the inside by a coating beam by means of a thermal spray apparatus
Data Source
AI summary
A component stack is coated such that, during a first coating pass, a first angle (α) is formed between the first stack opening surface and the coating beam and, during a second coating pass, a second angle (β) is formed between the first stack opening surface and the coating beam, wherein the first angle (α) and the second angle (β) are formed in opposite directions relative to the first stack opening surface.