Carbide-Forming Turbine Blade Tip Coating for Shroud Wear Resistance

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Solution Overview

Problem

Existing methods for forming abrasive materials on turbine blade tips are not durable for long-term engine use due to limitations in blade tip design resulting from fabrication techniques, leading to significant wear and reduced compressor or turbine performance.

Innovation Solution

A method involving the mixing of metal powder with carbon powder to form a carbon-enriched metal powder, which includes refractory elements like tungsten, tantalum, or titanium, and bonding this mixture to the turbine blade tip using laser deposition or electron-beam welding, causing the carbon to combine with these elements and form hard carbide particles that act as abrasives.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If abrasive particles are embedded in the blade tip using entrapment plating method, then the blade tip gains abrasive properties, but the blade tip design is limited and durability is reduced

Engineering Contradiction:

Improveblade tip durabilityVSAvoidblade tip design freedom

Core Design Contradiction:

ReliabilityVSAdaptability or versatility

Solution Approach 1:

The patent changes the fundamental parameters of the coating process by using laser deposition instead of entrapment plating, allowing for variable composition coatings that can be tailored to specific design requirements while maintaining durability. The laser deposition process enables precise control over coating thickness, composition, and microstructure.

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent employs composite material coatings consisting of metal matrix with embedded abrasive particles (such as boron carbide, cubic boron nitride, or silicon carbide). These composite coatings provide both the abrasive properties needed for rub tolerance and the structural integrity required for long-term durability, while allowing design flexibility.

Inventive Principle:

Principle #40Composite materials

2Object-affected harmful factors

If traditional abrasive coating methods are used, then abrasive properties are achieved, but significant blade tip wear occurs during rubbing

Engineering Contradiction:

Improveblade tip wear resistanceVSAvoidlong-term durability

Core Design Contradiction:

Object-affected harmful factorsVSReliability

Solution Approach 1:

The patent replaces mechanical embedding methods (entrapment plating) with a thermal-based laser deposition process. This substitution allows for better bonding between the coating and substrate, creating a more durable abrasive layer that resists wear during prolonged rubbing operations.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent applies abrasive coatings with locally optimized properties - the coating composition, thickness, and abrasive particle distribution can be tailored to specific regions of the blade tip based on expected rubbing conditions, thereby maximizing wear resistance where needed while maintaining overall blade performance.

Inventive Principle:

Principle #3Local quality

3Productivity

If blade tip dimensions are tightly controlled to minimize clearance, then compressor and turbine efficiency are maximized, but blade tips become susceptible to rubbing and wear

Engineering Contradiction:

Improvecompressor and turbine efficiencyVSAvoidblade tip rubbing and wear

Core Design Contradiction:

ProductivityVSObject-affected harmful factors

Solution Approach 1:

The patent applies abrasive coatings to blade tips in advance before service operation. This preliminary protection allows the blade tips to withstand rubbing encounters during tight-clearance operation without suffering significant wear, thereby maintaining the efficiency benefits of tight clearance control throughout the engine's operational life.

Inventive Principle:

Principle #9Preliminary anti-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 approach enhances the durability of turbine blade tips by forming abrasive carbide particles that can withstand rubbing against the shroud without significant wear, thereby improving compressor and turbine efficiency and extending engine life.

Implementation Method 1

raising the temperature of the carbon-enriched metal powder past its melting point, thereby causing the carbon to combine with the refractory elements to form abrasive carbide particles

Methodology Applied

Scientific EffectMelting: Melting

Implementation Method 2

causing the carbon to combine with the refractory elements to form abrasive carbide particles

Methodology Applied

Scientific EffectChemical Bonding: Chemical Bonding

Implementation Method 3

Bonding the carbon-enriched metal powder is performed using a laser deposition process

Methodology Applied

Scientific EffectLaser Beam Welding: Laser Beam Welding

Implementation Method 4

Bonding the carbon-enriched metal powder is performed using a laser deposition process or an electron-beam welding process

Methodology Applied

Scientific EffectElectron Beam: Electron Beam

Data Source

PatentUS10933469B2Method of forming an abrasive nickel-based alloy on a turbine blade tip

Publication Date: 2021.03.02 HONEYWELL INTERNATIONAL INC

AI summary

A method of forming an abrasive nickel-based alloy on a turbine blade tip includes producing or obtaining a metal powder that is mixed with a carbon powder to form a carbon-enriched metal powder. The metal powder includes a refractory element. The method further includes bonding the carbon-enriched metal powder to the turbine blade tip. The step of bonding includes raising the temperature of the carbon-enriched metal powder past its melting point, thereby causing the carbon to combine with the refractory elements to form abrasive carbide particles.