Turbine Blade Wear Coating Verification by Threshold Geometry
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Solution Overview
Problem
The existing methods for applying wear-proof coatings on turbine engine blades are inefficient, as they rely on manual operations and lack effective verification processes for conformity, leading to potential non-conformities that can affect the blades' performance and longevity.
Innovation Solution
A method for producing metal bladed elements that involves depositing a wear-proof coating and using a verification element to conceal or reveal non-conformities based on predetermined dimensional thresholds, ensuring the blades meet specific conformity levels (C1 or C2) through visual verification and potentially including machining and penetrant testing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If manual operations are used for depositing wear-proof coating on turbine blades, then flexibility and adaptability are maintained, but productivity is reduced and manufacturing precision is compromised
Solution Approach 1:
The verification element is designed to automatically verify coating conformity through its own geometric features (reference surfaces, edges) without requiring manual measurement tools or complex inspection procedures. The element itself performs the verification function that would otherwise require manual intervention
Solution Approach 2:
The verification element incorporates pre-defined reference surfaces and geometric features that establish conformity criteria before the coating process. By preparing the verification element in advance with precise reference geometries, the system eliminates the need for complex post-coating measurements and enables rapid verification
2Manufacturing precision
If manual verification processes are used for coating conformity, then flexibility is maintained, but measurement precision and reliability are insufficient
Solution Approach 1:
The verification element creates a physical copy or representation of the ideal coating geometry through its reference surfaces. By comparing the actual coating against this pre-defined geometric copy embedded in the verification element, precise measurement is achieved without complex measurement equipment
Solution Approach 2:
The verification element transforms the verification process from a complex multi-parameter measurement task into a simple visual or tactile comparison in a different dimension. The reference surfaces and edges provide a geometric framework that converts complex conformity assessment into straightforward dimensional comparison
3Reliability
If wear-proof coating is applied to protect blade edges, then durability and reliability are improved, but non-conformities in coating application may occur that affect performance
Solution Approach 1:
The verification element establishes the ideal coating geometry and conformity criteria before the coating process begins. By having the reference surfaces and verification features prepared in advance, any deviations in coating application can be immediately identified and corrected, ensuring consistent quality
Solution Approach 2:
The verification element provides immediate visual or tactile feedback on coating conformity by comparing the actual coating against the pre-defined reference geometry. This feedback mechanism enables real-time quality control during the coating process, allowing corrections to be made before defects become critical
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 approach simplifies and ensures the economic production of turbine engine blades by effectively verifying the conformity of the wear-proof coating, reducing the risk of non-conformities and improving the blades' durability and performance.
Implementation Method 1
verifying, sometimes visually, the conformity of the bladed element. Verifying includes implementing a verification element on the bladed element, this element being configured according to a conformity threshold to conceal a non-conformity of the coating
Data Source
AI summary
A method for producing a metal bladed element of a turbine engine, in particular of an aircraft, includes steps of producing the bladed element, depositing a coating made of wear-proof material on at least one portion of the bladed element and verifying, preferably visually, the conformity of the bladed element. Verifying the conformity of the bladed element includes implementing a verification element on the bladed element. The bladed element is configured according to a conformity threshold value to conceal a non-conformity of the coating, if the non-conformity has at least one dimension less than the threshold value, and to show at least one portion of this non-conformity if the at least one dimension is greater than the threshold value.