Turbine Component Patch Delivery via Compressed Gas
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Solution Overview
Problem
Silicon-containing components in gas turbines, such as SiC-based CMCs, face challenges with environmental barrier coatings that can develop defects like pinholes or spalls, leading to cavitation and reduced performance due to exposure to chemical environments, necessitating effective repair methods without disassembly.
Innovation Solution
A turbine component patch delivery system using a compressed gas source to project patch carriers with environmentally resistant patch materials, housed in breakaway shells, to fill voids and coat surfaces, ensuring adhesion, thermal expansion matching, and chemical protection, while allowing for in-situ repair without disassembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of repair
If traditional patch repair methods are used, then the component can be repaired, but the turbine must be disassembled which increases maintenance time and complexity
Solution Approach 1:
The patent replaces traditional mechanical patch application methods (requiring disassembly and manual application) with an automated delivery system that uses compressed gas to project patch carriers. This substitution eliminates the need for turbine disassembly while maintaining effective patch application, thereby reducing maintenance time and complexity.
Solution Approach 2:
The patent introduces an intermediary delivery system comprising compressed gas and patch carriers that mediate between the patch material and the turbine component surface. This intermediary system enables remote patch application without direct mechanical access, allowing repair without turbine disassembly.
2Strength
If patch material is applied to fill voids, then the structural integrity is improved, but the patch must withstand thermal expansion which increases device complexity
Solution Approach 1:
The patent applies parameter changes by selecting patch materials with specific physical and chemical properties matched to the turbine component substrate. The patch material is formulated to have compatible thermal expansion coefficients, chemical composition, and physical state to ensure proper adhesion and stress distribution under thermal cycling, thereby maintaining strength without requiring complex compensation mechanisms.
Solution Approach 2:
The patent employs composite materials for the patch that combine multiple functional properties: thermal stability, chemical resistance, mechanical strength, and matched thermal expansion characteristics. This composite approach allows a single patch material to address multiple requirements simultaneously, reducing overall system complexity while maintaining structural integrity.
3Reliability
If environmental barrier coating is applied, then the component is protected from chemical degradation, but localized defects can still occur leading to cavitation
Solution Approach 1:
The patent applies local quality by providing targeted patch repair at specific locations where environmental barrier coating defects occur. Rather than requiring complete coating replacement, the patch material is applied locally to fill voids and seal defects, providing enhanced protection precisely where needed while maintaining the overall integrity of the environmental barrier coating system.
Solution Approach 2:
The patent implements beforehand cushioning by applying patches proactively to prevent the propagation of cavitation and void growth. The patch material serves as a preventive barrier that stops harmful factors from penetrating deeper into the component, cushioning against potential failure before it occurs.
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 system effectively delivers and cures environmentally resistant patches to silicon-containing components, enhancing their durability and operational efficiency by preventing material loss and maintaining structural integrity under extreme conditions.
Implementation Method 1
a compressed gas source fluidly connected to a delivery line... one or more turbine component patch carriers that can be projected out of the dispensing end of the delivery line by the compressed gas source
Implementation Method 2
the breakaway shell breaks open to at least partially coat the surface of the turbine component with the turbine component patch material
Implementation Method 3
environmentally resistant patches for filling voids in silicon-containing components... patches that adhere to and protect the surface
Implementation Method 4
EBCs are generally selected to have a good match in their coefficient of thermal expansion (CTE) to that of the silicon-containing substrate material
Data Source
AI summary
A turbine component patch delivery system can include a compressed gas source fluidly connected to a delivery line comprising a dispensing end. The turbine component patch delivery system can further include one or more turbine component patch carriers that can be projected out of the dispensing end of the delivery line by the compressed gas source, wherein each of the one or more turbine component patch carriers comprise a turbine component patch material housed within a breakaway shell.