Vane Cluster Metallic Coating Uniformity

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Solution Overview

Problem

The existing methods for applying metallic coatings to gas turbine engine components, particularly vane clusters, result in non-uniform coating distribution due to the geometry of the vane clusters, leading to inadequate protection against thermal and oxidation conditions, as 'hidden' areas within the clusters receive insufficient coating, causing mismatched thermal gradients and growth.

Innovation Solution

A method involving a two-layer metallic coating application, where a first layer is applied using contact metal deposition, specifically electro-spark deposition, to the partially shadowed areas of the vane cluster, followed by a second layer applied using techniques like low pressure plasma spray or electron beam physical vapor deposition to ensure uniform coating across the entire surface.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If a single layer of metallic coating is applied to vane clusters using conventional methods, then the coating application process is simple and quick, but the coating distribution becomes non-uniform with hidden areas receiving insufficient coating

Engineering Contradiction:

Improvecoating uniformityVSAvoidcoating process complexity

Core Design Contradiction:

Manufacturing precisionVSDevice complexity

Solution Approach 1:

The coating process is divided into two distinct stages: a first coating pass that provides initial coverage, and a second coating pass that ensures uniform thickness. This segmentation allows each pass to be optimized for its specific purpose, resolving the contradiction between simplicity and uniformity by making the process slightly more complex but significantly more effective.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The first coating layer is applied as a preliminary action before the second layer. This preliminary coating establishes a base layer that ensures even the hidden areas receive minimum coverage, preparing the surface for the second pass that achieves uniform thickness across all surfaces including previously shadowed areas.

Inventive Principle:

Principle #10Preliminary action

2Reliability

If conventional coating methods are used on vane clusters, then the process is straightforward, but thermal protection becomes inadequate due to non-uniform coating distribution

Engineering Contradiction:

Improvethermal protection reliabilityVSAvoidcoating application ease

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The dual-pass coating approach enables different local qualities to be achieved: the first pass provides baseline coverage to all areas including hidden surfaces, while the second pass delivers uniform thickness to ensure adequate thermal protection. This local differentiation resolves the contradiction by making the process slightly more complex but significantly more reliable.

Inventive Principle:

Principle #3Local quality

3Manufacturing precision

If a single coating pass is used to minimize process time, then productivity is high, but coating thickness uniformity deteriorates with hidden areas being under-coated

Engineering Contradiction:

Improvecoating thickness uniformityVSAvoidcoating application speed

Core Design Contradiction:

Manufacturing precisionVSProductivity

Solution Approach 1:

The coating operation is segmented into two passes: a first pass that establishes baseline coverage and a second pass that achieves uniform thickness. While this increases total process time compared to a single pass, it dramatically improves coating quality by ensuring even hidden areas receive adequate and uniform coating, thus resolving the contradiction between speed and precision.

Inventive Principle:

Principle #1Segmentation

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 coating uniformity and effectiveness in providing thermal and oxidation resistance, ensuring consistent protection across all surfaces of the vane cluster, thereby improving the performance and longevity of gas turbine engine components.

Implementation Method 1

applying a first layer of metallic coating within a portion of a total surface of the at least two cluster vanes, wherein the first layer of metallic coating is applied within the portion of the total surface area of the vane cluster using a contact metal deposition process, such as an electro-spark deposition process

Methodology Applied

Scientific EffectElectrical discharge: Electric Spark

Implementation Method 2

applying a second layer of metallic coating to substantially the total surface of the at least two cluster vanes using techniques such as low pressure plasma spray

Methodology Applied

Scientific EffectPlasma spray: Plasma Spray

Implementation Method 3

electron beam physical vapor deposition

Methodology Applied

Scientific EffectElectron beam physical vapor deposition: Electron Beam

Data Source

PatentUS11143042B2System and method for applying a metallic coating

Publication Date: 2021.10.12 RTX CORP

AI summary

The present disclosure relates generally to a system and method for applying a metallic coating. A first metallic coating may be applied to a portion of a total surface of a part and a second metallic coating may be applied to substantially the total surface. The metallic coating may be applied to a vane cluster for use in a turbomachine.