Thermal Spray Coating Cooling Channel Protection

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Solution Overview

Problem

Thermal spray coatings often fill cooling channels in components, restricting the flow of cooling mediums and reducing their effectiveness.

Innovation Solution

A thermal spray coating method that positions a covering over cooling channels to prevent feedstock from entering, allowing for increased flow and efficiency of cooling mediums, using materials like mesh or foil that are resistant to deformation during spraying.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Temperature

If thermal spray coating is applied to protect components from high temperatures, then the component gains thermal protection, but the cooling channels become filled with feedstock, restricting cooling medium flow

Engineering Contradiction:

Improvethermal protectionVSAvoidcooling medium flow

Core Design Contradiction:

TemperatureVSProductivity

Solution Approach 1:

A covering is positioned over the cooling channels before thermal spray coating is applied. This preliminary protective measure prevents feedstock from entering the cooling channels during the coating process, ensuring that the cooling channels remain clear for proper cooling medium flow while still allowing the component to receive thermal protection coating on its external surfaces

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The component surface is segmented into protected areas (cooling channels) and treated areas (external surfaces). The covering selectively shields the cooling channels from coating material while allowing the rest of the component to be coated, creating distinct functional zones with different treatments

Inventive Principle:

Principle #1Segmentation

2Reliability

If thermal spray coating is applied to increase coating thickness for better protection, then thermal protection improves, but feedstock contamination in cooling channels increases

Engineering Contradiction:

Improvethermal protectionVSAvoidfeedstock contamination

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The covering is positioned in advance to prevent feedstock contamination during the thermal spray process. This preliminary protective measure ensures that even as coating thickness increases for better thermal protection, the cooling channels remain free from feedstock contamination that would restrict cooling medium flow

Inventive Principle:

Principle #10Preliminary action

3Ease of manufacture

If cooling channels are left open during thermal spraying, then coating application is simpler, but cooling efficiency is reduced due to feedstock blockage

Engineering Contradiction:

Improvecoating applicationVSAvoidcooling efficiency

Core Design Contradiction:

Ease of manufactureVSProductivity

Solution Approach 1:

The covering is positioned over the cooling channels before coating application begins. This simple preliminary step maintains high cooling efficiency by preventing feedstock blockage, while adding minimal complexity to the overall manufacturing process. The covering can be easily installed and removed, making the process straightforward

Inventive Principle:

Principle #10Preliminary action

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

This method enhances the effectiveness of thermal cooling channels by maintaining the flow of cooling mediums, reducing contamination, and decreasing coating thickness, thereby improving cooling efficiency and preventing heat damage to components.

Implementation Method 1

thermal spraying a feedstock onto the component and the covering

Methodology Applied

Scientific EffectThermal spray:

Implementation Method 2

The cooling medium transports heat away from a region of the component to provide cooling

Methodology Applied

Scientific EffectHeat transfer: Conduction (thermal)

Data Source

PatentUS10775115B2Thermal spray coating method and thermal spray coated article

Publication Date: 2020.09.15 GE INFRASTRUCTURE TECH LLC

AI summary

Thermal spray coating methods and thermal spray coated articles are disclosed. The thermal spray coating method includes positioning a covering on a cooling channel of a component, and thermal spraying a feedstock onto the covering. The covering prohibits the feedstock from entering the cooling channel in the component and is not removed from the component. In another embodiment, the thermal spray coating method includes providing a component comprising a substrate material, providing a cooling channel on a surface of the component, positioning a covering on the cooling channel, and thermal spraying a feedstock onto the component and the covering, the feedstock comprising a bond coat material. The covering prohibits the bond coat material from entering the cooling channel. The thermal spray coated article includes a component, a cooling channel, a covering on the cooling channel, and a thermally sprayed coating on the component and the covering.