Thermal Insulation Coating with Inclined Flat Pores for Turbine Durability
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Solution Overview
Problem
The durability of thermal insulation layers in axial flow turbines, particularly in narrow portions, is compromised due to the difficulty in projecting thermal spray particles at large angles, leading to peeling and reduced thermal insulation effectiveness.
Innovation Solution
A thermal insulation coating member comprising a substrate with a binding layer and a thermal insulation layer composed of multiple ceramic layers with flat pores inclined at different angles and directions, enhancing peeling resistance and durability even in narrow areas.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If thermal spray particles are projected at a small angle onto the surface of the high-temperature member, then the manufacturing process becomes easier in narrow portions, but the durability of the thermal insulation layer decreases and peeling occurs
Solution Approach 1:
The thermal insulation layer is divided into multiple layers (first thermal insulation layer, second thermal insulation layer, third thermal insulation layer) with different pore orientations. Each layer is formed by thermal spraying from different directions, creating a segmented structure where pores in adjacent layers have different inclination angles relative to the surface normal, preventing peeling while maintaining manufacturability in narrow portions
Solution Approach 2:
Different regions of the thermal insulation layer have different pore structures and orientations. The first thermal insulation layer has pores inclined at a first angle, the second layer has pores inclined at a second angle, and the third layer has pores inclined at a third angle. This local variation in pore quality provides both peeling resistance and adaptability to narrow portion constraints
2Reliability
If thermal spray particles are projected at a large angle onto the surface of the high-temperature member, then the durability of the thermal insulation layer is enhanced, but it becomes difficult to perform thermal spraying in narrow portions
Solution Approach 1:
The thermal insulation layer is divided into multiple layers (first thermal insulation layer, second thermal insulation layer, third thermal insulation layer) with different pore orientations. Each layer is formed by thermal spraying from different directions, creating a segmented structure where pores in adjacent layers have different inclination angles relative to the surface normal, preventing peeling while maintaining manufacturability in narrow portions
Solution Approach 2:
The solution moves from considering only a single spraying angle to utilizing multiple dimensions of pore orientation by forming layers with pores inclined at different angles (first angle, second angle, third angle). This dimensional approach allows thermal spraying to be performed from various directions, making narrow portions accessible while maintaining durability
3Ease of manufacture
If the thermal insulation layer is formed by thermal spraying with particles projected at a small angle, then the thermal insulation layer can be formed in narrow portions, but the thermal insulation layer may be peeled off from the high-temperature member
Solution Approach 1:
The thermal insulation layer is divided into multiple layers (first thermal insulation layer, second thermal insulation layer, third thermal insulation layer) with different pore orientations. Each layer is formed by thermal spraying from different directions, creating a segmented structure where pores in adjacent layers have different inclination angles relative to the surface normal, preventing peeling while maintaining manufacturability in narrow portions
Solution Approach 2:
The thermal insulation layer is constructed as a composite structure with multiple layers having different pore characteristics. The first thermal insulation layer has pores with a first orientation, the second layer has pores with a second orientation, and the third layer has pores with a third orientation. This composite structure combines the advantages of different pore configurations to achieve both formability in narrow portions and resistance to peeling
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 maintains high thermal insulation and durability of the thermal insulation layer in narrow portions, equivalent to conventional thermal spraying methods, while improving manufacturability by ensuring the thermal insulation layer's peeling resistance and strength.
Implementation Method 1
The "thermal spraying" refers to a method of forming a layer by projecting particles (hereinafter, referred to as "thermal spray particles") onto the surface of the high-temperature member while melting them
Implementation Method 2
a thermal insulation layer made of ceramic having a thermal conductivity lower than that of metal is coated on the surface of the high-temperature member
Data Source
AI summary
A thermal insulation coating member includes: a substrate having a surface; a binding layer on the surface, and a thermal insulation layer on the binding layer. The thermal insulation layer includes: a first ceramic layer including a plurality of first flat pores, the plurality of first flat pores being inclined at a first angle with respect to the surface and extending in a first direction; and a second ceramic layer including a plurality of second flat pores, the plurality of second flat pores being inclined at a second angle with respect to the surface and extending in a second direction. The second angle differs from the first angle, the second direction differing from the first direction, or the second angle and the second direction respectively differing from the first angle and the first direction.