U.S. patent application number 17/655892 was filed with the patent office on 2022-07-07 for process for coating substrates with aperture(s).
The applicant listed for this patent is General Electric Company. Invention is credited to Fernando Jorge Casanova, Kassy Moy Hart, Anderson Viaro Mattos, William Clifford Ross, David Allen Singletary, Jose Troitino Lopez, John Thomas Zanetti.
Application Number | 20220213583 17/655892 |
Document ID | / |
Family ID | |
Filed Date | 2022-07-07 |
United States Patent
Application |
20220213583 |
Kind Code |
A1 |
Singletary; David Allen ; et
al. |
July 7, 2022 |
PROCESS FOR COATING SUBSTRATES WITH APERTURE(S)
Abstract
A coating method for a component with at least one aperture
includes providing a component having at least one aperture formed
in a surface thereof; additively manufacturing a hollow member on a
portion of the surface to define a space above each aperture, the
portion of the surface being adjacent to the aperture, the hollow
member having an inner peripheral geometry complementary to a
peripheral geometry at least one of aperture; applying at least one
coating over the surface of the component and around hollow member
to form an applied coating having an applied coating thickness; and
removing at least a portion of the hollow member to make a top
portion of the hollow member coplanar with the applied coating to
expose the space through the applied coating; wherein a lower
portion of the hollow member remains to define the space through
the applied coating.
Inventors: |
Singletary; David Allen;
(Greenville, SC) ; Zanetti; John Thomas;
(Greenville, SC) ; Hart; Kassy Moy; (Greenville,
SC) ; Ross; William Clifford; (Monroe, OH) ;
Troitino Lopez; Jose; (Miami, FL) ; Mattos; Anderson
Viaro; (Greenville, SC) ; Casanova; Fernando
Jorge; (Simpsonville, SC) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
General Electric Company |
Schenectady |
NY |
US |
|
|
Appl. No.: |
17/655892 |
Filed: |
March 22, 2022 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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16849418 |
Apr 15, 2020 |
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17655892 |
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International
Class: |
C23C 4/11 20060101
C23C004/11; B33Y 80/00 20060101 B33Y080/00; C23C 4/134 20060101
C23C004/134; B33Y 40/20 20060101 B33Y040/20; B32B 3/26 20060101
B32B003/26; C23C 14/08 20060101 C23C014/08; C23C 14/30 20060101
C23C014/30 |
Claims
1. A coated component, the component comprising: a surface; at
least one aperture formed in the surface; a coating layer on the
surface, the coating layer including: at least one hollow member on
the surface extending from the surface to an outer surface of the
coating layer, each hollow member defining a space above a
respective one of the at least one aperture, a perimeter of each
hollow member being coincident with a perimeter of a respective one
of the at least one aperture and having an inner peripheral
geometry complementary to an inner peripheral geometry of the
respective one of the at least one aperture; a coating material on
the surface and around the at least one hollow member, the coating
material having a top surface coplanar with a portion of the at
least one hollow member.
2. The coated component of claim 1, wherein the coating material
includes at least one of a thermal barrier coating composition, an
environmental barrier coating composition, or a bond coat
composition.
3. The coated component of claim 1, wherein the at least one hollow
member includes at least one of a thermal barrier coating
composition, an environmental barrier coating composition, or a
bond coat composition.
4. The coated component of claim 1, wherein the at least one hollow
member is formed with the respective one of the at least one
aperture.
5. The coated component of claim 1, wherein the at least one hollow
member is formed by additively manufacturing the at least one
hollow member on the surface and extending from the surface to an
outer surface of the at least one hollow member.
6. The coated component of claim 1, wherein the at least one hollow
member includes an inner periphery aligned with an outer perimeter
of the respective one of the at least one aperture.
7. The coated component of claim 1, wherein the at least one
aperture defines an axis disposed at a non-perpendicular angle to
the surface, and a respective at least one hollow member is coaxial
with an axis of the at least one aperture.
8. The coated component of claim 1, wherein the component is a
turbomachine component.
9. The coated component of claim 1, wherein the at least one hollow
member includes a ceramic material selected from a group including
at least one of aluminum-oxide, zirconium-oxide, hafnium-oxide,
yttria-stabilized zirconium-oxide, metallic material, silicon based
material, graphite, aluminum oxide, yttria-stabilized zirconia.
10. The coated component of claim 1, wherein the coating material
includes a ceramic material selected from a group including at
least one of aluminum-oxide, zirconium-oxide, hafnium-oxide,
yttria-stabilized zirconium-oxide, metallic material, silicon based
materials, graphite, aluminum oxide, or yttria-stabilized
zirconia.
11. The coated component of claim 1, wherein an inner periphery of
the at least one hollow member aligns with an outer perimeter of
the at least one aperture to define a coplanar transitional
surface.
12. The coated component of claim 1, wherein the coating material
is applied by spraying the coating material with a spray gun
disposed at an angle to the at least one aperture.
Description
[0001] This application is a Divisional application of U.S. patent
application Ser. No. 16/849,418 filed Apr. 15, 2022, now U.S. Pat.
No. ______, the entire contents of which are fully incorporated
herein.
BACKGROUND
[0002] The disclosure relates generally to methods for coating
substrates. In particular, the present disclosure is directed to
coating methods for selectively coating a substrate that includes
apertures, and a coated substrate that includes apertures formed by
the coating methods.
[0003] When turbines are used on aircraft or for power generation,
they are typically run at a temperature as high as possible, for
increased operating efficiency. Since high temperatures can damage
the alloys used for the components, a variety of approaches have
been used to raise the operating temperature of metal components.
One approach calls for the incorporation of internal cooling
channels in the component, through which cool air is forced during
engine operation. Apertures or cooling holes can be formed in the
substrate by techniques such as water jet processing and/or
electrical discharge machining (EDM). Cooling air (usually provided
by the engine's compressor) is fed through the holes from the
cooler side to the hot side of a component wall. As long as the
holes remain clear, the rushing air will assist in lowering the
temperature of the hot metal surface and preventing melting or
other degradation of the component.
[0004] Another technique for protecting the metal parts and
effectively raising the practical operating temperature involves
the use of a coating, such as a bond coat, a thermal barrier
coating (TBC) or environmental barrier coating (EBC). A TBC is
usually ceramic-based. Coating systems frequently also include a
bond coat which is placed between the ceramic coating and the
substrate to improve adhesion. Use of TBCs in conjunction with
cooling holes is sometimes an effective means for protecting an
engine part. However, incorporation of both systems can be very
difficult. For example, cooling holes sometimes cannot be formed in
the engine part after a TBC has been applied, since lasers usually
cannot effectively penetrate both ceramic material and metal to
form the pattern of holes and may possibly crack a TBC. If cooling
holes are formed prior to the application of a coating system, they
may become covered and at least partially obstructed when a coating
is applied.
BRIEF DESCRIPTION
[0005] A first aspect of the disclosure provides a coating method
for a component with at least one aperture. The coating method
includes providing a component having at least one aperture formed
in a surface thereof; additively manufacturing a hollow member on a
portion of the surface to define a space above each aperture, the
portion of the surface being adjacent to the aperture, the hollow
member having an inner peripheral geometry complementary to a
peripheral geometry at least one of aperture; applying at least one
coating over the surface of the component and around the hollow
member to form an applied coating having an applied coating
thickness; and removing at least a portion of the hollow member to
make a top portion of the hollow member coplanar with the applied
coating to expose the space through the applied coating; wherein a
lower portion of the hollow member remains to define the space
through the applied coating.
[0006] A second aspect of the disclosure provides a coated
component. The component includes a surface; at least one aperture
formed in the surface; a coating layer on the surface, the coating
layer including: at least one hollow member additively manufactured
on the surface extending from the surface to a top surface, each
hollow member defining a space above a respective one of the at
least one aperture, a perimeter of the hollow member being
coincident with each at least one aperture and having an inner
peripheral geometry complementary to a peripheral geometry the
respective one of the at least one of the aperture; a coating
material sprayed on the surface and around the hollow member, the
coating material having a top surface coplanar with a portion of
the hollow member after portions of at least one of the hollow
member is removed.
[0007] All aspects, examples and features mentioned below can be
combined in any technically possible way.
[0008] An aspect of the disclosure provides a coated component,
with the component comprising a surface; at least one aperture
formed in the surface; a coating layer on the surface, wherein the
coating layer including at least one hollow member on the surface
extending from the surface to an outer surface of the coating
layer, each hollow member defining a space above a respective one
of the at least one aperture, a perimeter of each hollow member
being coincident with a perimeter of a respective one of the at
least one aperture and having an inner peripheral geometry
complementary to an inner peripheral geometry of the respective one
of the at least one aperture; a coating material on the surface and
around the at least one hollow member, the coating material having
a top surface coplanar with a portion of the at least one hollow
member.
[0009] Another aspect of the disclosure includes any of the
preceding aspects, and the coating material includes at least one
of a thermal barrier coating composition, an environmental barrier
coating composition, or a bond coat composition.
[0010] Another aspect of the disclosure includes any of the
preceding aspects, and the at least one hollow member includes at
least one of a thermal barrier coating composition, an
environmental barrier coating composition, or a bond coat
composition.
[0011] Another aspect of the disclosure includes any of the
preceding aspects, and the at least one hollow member is formed
with the respective one of the at least one aperture.
[0012] Another aspect of the disclosure includes any of the
preceding aspects, and the at least one hollow member is formed by
additively manufacturing the at least one hollow member on the
surface and extending from the surface to an outer surface of the
at least one hollow member.
[0013] Another aspect of the disclosure includes any of the
preceding aspects, and the at least one hollow member includes an
inner periphery aligned with an outer perimeter of the respective
one of the at least one aperture.
[0014] Another aspect of the disclosure includes any of the
preceding aspects, and the at least one aperture defines an axis
disposed at a non-perpendicular angle to the surface, and a
respective at least one hollow member is coaxial with an axis of
the at least one aperture.
[0015] Another aspect of the disclosure includes any of the
preceding aspects, and the component is a turbomachine
component.
[0016] Another aspect of the disclosure includes any of the
preceding aspects, and the at least one hollow member includes a
ceramic material selected from a group including at least one of
aluminum-oxide, zirconium-oxide, hafnium-oxide, yttria-stabilized
zirconium-oxide, metallic material, silicon based material,
graphite, aluminum oxide, yttria-stabilized zirconia.
[0017] Another aspect of the disclosure includes any of the
preceding aspects, and the coating material includes a ceramic
material selected from a group including at least one of
aluminum-oxide, zirconium-oxide, hafnium-oxide, yttria-stabilized
zirconium-oxide, metallic material, silicon based materials,
graphite, aluminum oxide, or yttria-stabilized zirconia.
[0018] Another aspect of the disclosure includes any of the
preceding aspects, and an inner periphery of the at least one
hollow member aligns with an outer perimeter of the at least one
aperture to define a coplanar transitional surface.
[0019] Another aspect of the disclosure includes any of the
preceding aspects, and the coating material is applied by spraying
the coating material with a spray gun disposed at an angle to the
at least one aperture.
[0020] Two or more aspects described in this disclosure, including
those described in this summary section, may be combined to form
implementations not specifically described herein.
[0021] The details of one or more implementations are set forth in
the accompanying drawings and the description below. Other
features, objects and advantages will be apparent from the
description and drawings, and from the claims.
[0022] The illustrative aspects of the present disclosure are
designed to solve the problems herein described and/or other
problems not discussed.
BRIEF DESCRIPTION OF THE DRAWINGS
[0023] These and other features of this disclosure will be more
readily understood from the following detailed description of the
various aspects of the disclosure taken in conjunction with the
accompanying drawings that depict various embodiments of the
disclosure, in which:
[0024] FIG. 1 is a perspective view of a component of the present
disclosure;
[0025] FIG. 2 is a flow chart of a process according to the present
disclosure;
[0026] FIG. 3 is a sectional view of a component of FIG. 1
including a plurality of apertures with hollow members formed
thereon according to the present disclosure;
[0027] FIG. 4 is a sectional view of a component of FIG. 1
including a plurality of apertures with hollow members and coating
formed thereon according to the present disclosure;
[0028] FIG. 5 is a sectional view of a component of FIG. 1
including a plurality of apertures with hollow members and coating
formed thereon with portions of hollow members removed according to
the present disclosure;
[0029] FIG. 6 is a sectional view of a component according to
another aspect of the present disclosure including a plurality of
apertures with hollow members formed thereon according to the
present disclosure;
[0030] FIG. 7 is a sectional view of a component according to
another aspect of the present disclosure including a plurality of
apertures with hollow members and coating formed thereon according
to the present disclosure;
[0031] FIG. 8 is a sectional view of a component according to
another aspect of the present disclosure including a plurality of
apertures with hollow members and coating formed thereon with
portions of hollow members removed according to the present
disclosure; and
[0032] FIG. 9 is an illustration of a spray apparatus with a
component according to the present disclosure.
[0033] It is noted that the drawings of the disclosure are not to
scale. The drawings are intended to depict only typical aspects of
the disclosure, and therefore should not be considered as limiting
the scope of the disclosure. In the drawings, like numbering
represents like elements between the drawings.
DETAILED DESCRIPTION
[0034] As an initial matter, in order to clearly describe the
current technology, it will become necessary to select certain
terminology when referring to and describing relevant components
within turbines. To the extent possible, common industry
terminology will be used and employed in a manner consistent with
its accepted meaning. Unless otherwise stated, such terminology
should be given a broad interpretation consistent with the context
of the present application and the scope of the appended claims.
Those of ordinary skill in the art will appreciate that often a
particular component may be referred to using several different or
overlapping terms. What may be described herein as being a single
part may include and be referenced in another context as consisting
of multiple components. Alternatively, what may be described herein
as including multiple components may be referred to elsewhere as a
single part.
[0035] In addition, several descriptive terms may be used regularly
herein, and it should prove helpful to define these terms at the
onset of this section. These terms and their definitions, unless
stated otherwise, are as follows. As used herein, "downstream" and
"upstream" are terms that indicate a direction relative to the flow
of a fluid, such as the working fluid through the turbine engine
or, for example, the flow of air through the combustor or coolant
through one of the turbine's component systems. The term
"downstream" corresponds to the direction of flow of the fluid, and
the term "upstream" refers to the direction opposite to the flow.
The terms "forward" and "aft," without any further specificity,
refer to directions, with "forward" referring to the front or
compressor end of the engine, and "aft" referring to the rearward
or turbine end of the engine.
[0036] It is often required to describe parts that are disposed at
differing radial positions with regard to a center axis. The term
"radial" refers to movement or position perpendicular to an axis.
For example, if a first component resides closer to the axis than a
second component, it will be stated herein that the first component
is "radially inward" or "inboard" of the second component. If, on
the other hand, the first component resides further from the axis
than the second component, it may be stated herein that the first
component is "radially outward" or "outboard" of the second
component. The term "axial" refers to movement or position parallel
to an axis. Finally, the term "circumferential" refers to movement
or position around an axis. It will be appreciated that such terms
may be applied in relation to the center axis of the turbine.
[0037] In addition, several descriptive terms may be used regularly
herein, as described below. The terms "first", "second", and
"third" may be used interchangeably to distinguish one component
from another and are not intended to signify location or importance
of the individual components.
[0038] The terminology used herein is for the purpose of describing
particular embodiments only and is not intended to be limiting of
the disclosure. As used herein, the singular forms "a", "an" and
"the" are intended to include the plural forms as well, unless the
context clearly indicates otherwise. It will be further understood
that the terms "comprises" and/or "comprising," when used in this
specification, specify the presence of stated features, integers,
steps, operations, elements, and/or components but do not preclude
the presence or addition of one or more other features, integers,
steps, operations, elements, components, and/or groups thereof.
"Optional" or "optionally" means that the subsequently described
event or circumstance may or may not occur, and that the
description includes instances where the event occurs and instances
where it does not.
[0039] Where an element or layer is referred to as being "on,"
"engaged to," "connected to" or "coupled to" another element or
layer, it may be directly on, engaged, connected, or coupled to the
other element or layer, or intervening elements or layers may be
present. In contrast, when an element is referred to as being
"directly on," "directly engaged to," "directly connected to" or
"directly coupled to" another element or layer, there may be no
intervening elements or layers present. Other words used to
describe the relationship between elements should be interpreted in
a like fashion (e.g., "between" versus "directly between,"
"adjacent" versus "directly adjacent," etc.). As used herein, the
term "and/or" includes any and all combinations of one or more of
the associated listed items.
[0040] As indicated above, the disclosure provides methods for
coating components. In particular, the present disclosure is
directed to coating methods for selectively coating a component
that includes apertures, and a coated component that includes
apertures formed by coating methods.
[0041] Referring to FIG. 1, in one embodiment, a component 100
includes any suitable component having at least one aperture 109
formed therein. In another embodiment, component 100 includes any
suitable component used in applications that undergo temperature
changes, such as, but not limited to, power generation systems
(e.g., gas turbines, jet turbines, and other turbine assemblies).
Suitable illustrative components 100 include, but are not limited
to: a nozzle, a blade, a vane, a shroud, a bucket, a transition
piece, a liner, or a combination thereof. Aperture 109 includes any
opening formed in an external surface 102 of component 100, such
as, but not limited to: a cooling hole (e.g., a trench cooling
hole, a diffuser shape cooling hole, a straight cooling hole, an
angled cooling hole), an opening to provide fuel flow, or a
combination thereof, and other cooling hole configurations now
known or hereinafter developed.
[0042] For example, as shown in FIG. 1, component 100 is
illustratively shown as a turbine blade having an airfoil section
103, a platform section 105, and a dovetail section 107. Airfoil
section 103 has a plurality of apertures 109 functioning as cooling
holes formed therein.
[0043] In one embodiment, component 100 is fabricated from a high
temperature oxidation and corrosion resistant alloy with high
temperature strength, such as a nickel-based, cobalt-based, or
iron-based superalloy. In another embodiment, component 100
includes a coating 400 (FIG. 4) applied over an external surface
102 of the component. Coating 400 can include any suitable coating
covering at least a portion of external surface 102 and/or
providing protection (e.g., increased heat tolerance, increased
corrosion resistance) to external surface 102, such as, but not
limited to, a bond coat, a thermal barrier coating (TBC), an
environmental barrier coating (EBC), or a combination thereof, or
other coatings now known or hereinafter developed. Suitable
examples of the bond coat include, but are not limited to: MCrAlX
coatings, where M is cobalt, nickel, iron, or combinations thereof,
X is an active element, such as yttrium (Y) and/or silicon (Si)
and/or at least one rare earth element or hafnium (Hf). Suitable
examples of the TBC include, but are not limited to, ceramic
coatings such as zirconium oxide (ZrO.sub.2), the crystalline
structure of which may be partially or completely stabilized by
adding yttrium oxide (Y.sub.2O.sub.3), aluminum-oxide,
zirconium-oxide, hafnium-oxide, yttria-stabilized zirconium-oxide,
metallic material, silicon based materials, graphite, aluminum
oxide, yttria-stabilized zirconia, and combinations thereof or
other coatings now known or hereinafter developed. In general, an
EBC system includes of two or more layers (for example, a bond coat
and/or a thermal barrier coat) of coating materials often rare
earth or yttrium silicates, in which each layer serves a specific
purpose. Thus, this disclosure will focus on application of a
layer, as an EBC may contain layers (so addressing a layer will
address a plurality of layers in an EBC) t.
[0044] Referring to FIGS. 2-5, in one embodiment, a first coating
method 200 includes providing component 100 (step 201) having
aperture 109 formed in external surface 102 thereof, then
additively manufacturing/printing at least one hollow member 300
(step 203) (FIG. 3) on a portion of external surface 102 at
aperture 109 to define a space 309 (FIG. 4) above aperture 109.
After hollow member 300 is printed (step 203), at least one coating
is applied (step 205) over external surface 102 of component 100
and around hollow member 300 to form a layer of coating 400 (FIG.
4) having an applied coating thickness 403 (FIG. 3).
[0045] Once coating 400 has been formed, a portion of hollow member
300 is removed (step 207) to expose space 309 through coating 400
to aperture 109. Alternatively, if desired and to reduce the
overall thickness of coating 400, portion of coating 400 can be
removed with removal of a portion of hollow member 300 (step 207),
thus exposing space 309 through coating 400 to aperture 109 with
the reduced coating thickness 410.
[0046] In one embodiment, hollow member 300 includes a geometry
complementary to aperture 109. Suitable complementary geometries
for aperture 109 and hollow member 300 include, but are not limited
to, tubular, semi-spherical, square, rectangular, cylindrical,
elliptical, hour-glass, chevron, any other complementary geometry
capable of extending from external surface 102 at aperture 109
(e.g., in a planar or non-planar manner), or combinations thereof.
For example, in one embodiment, the geometry of hollow member 300
is complementary to a diffuser-shaped cooling hole.
[0047] Hollow member 300 is printed on external surface 102 of
component 100 with any suitable height for forming a space 309
coextensive with coating 400 after step 207. Walls of space 309 are
formed by the inner walls of hollow member 300, which are
essentially collinearly equal to walls of apertures 109.
[0048] For example, hollow member 300 is printed on component 100
external surface 102 around an aperture 109 to extend away from
external surface 102 of component 100 with a height greater than or
equal to applied coating thickness 403 (see FIG. 3 or FIG. 5).
Suitable coating thickness 403 heights include, but are not limited
to, up to about 2.5 millimeters (0.1 inch).
[0049] In another aspect, inner perimeter 310 and geometry of
hollow member 300 are aligned, equal to, and complementary to an
outer perimeter 111 and geometry of aperture 109. This
configuration puts aperture 109 and hollow member 300 coaxial with
each other. The configuration also permits a smooth linear
transition from aperture 109 to hollow member 300, essentially
forming a coplanar transitional inner surface from aperture 109 to
hollow member 300.
[0050] Hollow member 300 is formed by any suitable 3-D printing
process, printing process, or additive manufacturing processes
(hereinafter collectively "additive manufacturing processes"), such
as, but not limited to, a wide variety of processes of producing a
component through the successive layering of material rather than
the removal of material. As such, additive manufacturing can create
complex geometries for hollow member 300 without the use of any
sort of tools, molds, or fixtures, and with little or no waste
material. Instead of machining hollow member 300 from solid billets
of material, much of which is cut away and discarded, the only
material used in additive manufacturing is what is required to
print hollow member 300.
[0051] Additive manufacturing techniques typically include taking a
three-dimensional computer aided design (CAD) file of the component
to be formed (here hollow member 300 on a build platform formed by
external surface 102 of component 100), electronically slicing the
component into layers, e.g., 18-102 micrometers thick, and creating
a file with a two-dimensional image of each layer, including
vectors, images, or coordinates. The file may then be loaded into a
preparation software system that interprets the file such that
hollow member 300 can be built by different types of additive
manufacturing systems. In 3D printing, rapid prototyping (RP), and
direct digital manufacturing (DDM) forms of additive manufacturing,
material layers are selectively dispensed, sintered, formed,
deposited, etc., to create the hollow member 300.
[0052] In powder additive manufacturing techniques, such as direct
metal laser melting (DMLM) (also referred to as selective laser
melting (SLM)), powder layers are sequentially melted together to
form the component. More specifically, fine powder layers are
sequentially melted after being uniformly distributed using an
applicator on a powder bed. Each applicator includes an applicator
element in the form of a lip, brush, blade, or roller made of
metal, plastic, ceramic, carbon fibers or rubber that spreads the
powder evenly over the build platform. The powder bed can be moved
in a vertical axis. The process takes place in a processing chamber
having a precisely controlled atmosphere. Once each layer is
created, each two-dimensional slice of the component geometry can
be fused by selectively melting the powder. The melting may be
performed by a high powered melting beam, such as but not limited
to, a 100 Watt ytterbium laser, to fully weld (melt) the metal
powder to form a solid. The melting beam moves in the X-Y direction
using scanning mirrors and has an intensity sufficient to fully
weld (melt) the powder to form a solid. The powder bed may be
lowered for each subsequent two-dimensional layer, and the process
repeats until the component is completely formed.
[0053] Referring again to FIGS. 2-5, after printing/additively
manufacturing hollow member 300 (step 203), at least one coating
400 is applied (step 205) over external surface 102 of component
100 by any suitable application method for forming coating 400 with
applied coating thickness 403. Suitable application methods
include, but are not limited to air plasma spray, high velocity
oxygen fuel (HVOF) thermal spray, or electron beam physical vapor
deposition or other application method now know or hereinafter
developed. During the application (step 205) of the at least one
coating, orientation and geometry of hollow member 300 with respect
to the coating being applied (as described hereinafter) reduces or
eliminates deposition of coating 400 material in any portion of
hollow member 300 (e.g., aperture 109 and space 309 (see FIG.
4)).
[0054] Once coating(s) 400 has been applied (step 205), upper
portion 301 of hollow member 300 may be removed (Step 207).
Moreover, as noted herein, a portion of coating 400 can be
optionally removed by any suitable removal method to provide the
desired coating thickness 403, if applied coating 400 (Step 205) is
too thick. Thus, top surface 410 (FIG. 5) of coating 400 will be
coplanar with the remaining portions of hollow member 300, after
removal. Suitable removal methods include, but are not limited to
machining, sanding, grit-blasting etching, polishing, or a
combination thereof. For example, in one embodiment, the coating
removal includes polishing coating 400 with a diamond pad.
[0055] In one aspect of the disclosure, upper portion 301 (FIG. 4)
of hollow member 300 includes an upper geometry that differs from a
lower geometry of lower portion 303. For example, hollow member 350
in FIG. 4 includes a rectangular printed upper section, which is
merely illustrative and not intended to limit the embodiments of
the disclosure in any manner. This different upper geometry may be
such that hollow member 300, if open at the end remote from
aperture 109 (see hollow member 320 in FIG. 4 with open end 321) is
configured to exclude coating 400 from entering hollow member 300.
With printing/additively manufacturing the hollow member 300, upper
portion 301 can be closed (see hollow member 330 in FIG. 4), or
open to a degree resisting entry of coating 400, especially if
coating 400 is sprayed.
[0056] Furthermore, as discussed herein, lower portion 303 geometry
may conform to the geometry of aperture 109, and upper geometry 301
may confirm to the geometry of aperture 109 or include any other
configuration or shape extending from lower portion 303. For
example, and in no way intended to limit the disclosure, hollow
member 300 at lower portion 303 may include a conforming geometry
to a circular aperture 109 transitioning to an ellipsoid geometry
in upper portion 301 extending away from external surface 102.
[0057] When upper portion 301 is removed (step 207) parts of upper
and lower portions 301, 303 remain to define space 309, as shown in
FIG. 5. In one embodiment, the geometry of the space 309 includes,
but is not limited to: cylindrical, spherical, square, rectangular,
domed, oblong, trapezoidal, curved, straight, skewed, irregular,
any other shape permitting flow therethrough, or a combination
thereof.
[0058] A further aspect of the disclosure includes
printing/additively manufacturing angled hollow members 500 in
conjunction with angled apertures 102 (including but not limited to
those used for film cooling turbine components), as illustrated in
FIGS. 6-8. Like reference characters are used for like
elements.
[0059] In FIGS. 6-8, angled hollow members 500 are printed on a
portion of external surface 102 at angled aperture 109 to define a
space 509 above angled aperture 109, usually oval or ellipsoid
given the intersecting aperture 109 at surface 102. As in the above
embodiments, angled hollow member 500 includes a geometry
complementary to aperture 109. Also, inner perimeter 510 and
geometry of angled hollow member 500 can be equal to and
complementary to an outer perimeter 111 and geometry of angled
aperture 109 at surface 102. Accordingly, angled aperture 109 and
angled hollow member 500 essentially form a coplanar transitional
surface from angled aperture 109 to hollow member 500, and hollow
member 500 is essentially collinear with walls of angled apertures
109.
[0060] Hollow member 500 is printed on external surface 102 of
component 100 with any suitable height for forming a space 509 with
the to-be-applied coating 400. Walls of space 509 are formed by the
inner walls of hollow member 500, with walls of space 509
essentially collinear to walls of apertures 109.
[0061] Hollow member 500 is printed (in any suitable printing or
additive manufacturing process as described above) on component 100
external surface 102 around angled aperture 109 to extend away from
external surface 102 of component 100 at an angle coincident with
the angle of aperture 109. This configuration puts aperture 109 and
hollow member 500 coaxial with each other. As above, hollow member
500 has a height greater than or equal to the applied coating
thickness 403.
[0062] After printing/additively manufacturing hollow member 500,
at least one coating 400 is applied over external surface 102 of
component 100 by any suitable application method for forming
coating 400 with applied coating thickness 403. During the
application of coating(s) 400, the orientation and geometry of
hollow member 500 being angled with respect to an
applicator/sprayer of coating material reduces or eliminates
coating material on or in aperture 109 and space 509. When upper
portion 501 is removed as in FIG. 8, parts of upper and lower
portions 501, 503 remain to define space 509. Thus, top surface of
coating 410 is coplanar with the remaining portions of hollow
member 500, after removal. Moreover, if needed to achieve a desired
coating thickness 403, removal of some portion of coating(s) 400
can occur with removal of hollow member 500.
[0063] With respect to a process for applying coating 400, as
discussed above, coating(s) 400 is applied over external surface
102 of component 100 by any suitable applicator/sprayer and
application method for forming coating 400 with applied coating
thickness 403. One suitable application method, as noted above, is
by spraying coating(s) 400.
[0064] With any of the embodiments herein, a spraying coating
applicator/sprayer may include a spray gun with a spray head that
can be disposed at an angle with respect to apertures 109 in
component 100. An angled spray head is effective to reduce spray
entering aperture 109, as angles of aperture 109 (including those
essentially orthogonal to surface 102) and of hollow members 300,
500 and may not align with the spray, thus spray should not
directly enter apertures 109. Moreover, as apertures 109 are
provided with printed hollow members 300, 500, angled spray heads
can provide enhanced coverage between apertures 109 and hollow
members 300, 500. With hollow members 300, 500 any spray and
coating(s) 400 should be kept from entering apertures 109, which
enables more efficient and effective consumption of coating without
wasted spray in apertures 109 needing to be removed and
scrapped.
[0065] FIG. 9 illustrates this aspect of the embodiments with spray
gun 550 having an angled spray head 555. Moreover, angled spray
head 555 can be an adjustable angled spray head 555 to move its
orientation to surface 102 between 0 degrees (orthogonal to surface
102) to almost 90 degrees or almost parallel to surface 102. As is
illustrated, angled spray head 555 can have a direct line of spray
in-between printed hollow members, as shown for a set 500A of
hollow members, or have an offset line of spray in-between printed
hollow members, as shown for a set 500B of hollow members. One
desirable angle is about 20 degrees from orthogonal, however that
angle is not intended to limit the embodiments in any manner. With
hollow members 300, 500 spray and coating are kept from entering
apertures 109, which enables more efficient and effective
consumption of coating without wasted spray in apertures 109
needing to be removed and scrapped.
[0066] One advantage of an embodiment of the present disclosure
includes maintaining original shape and dimension of apertures or
cooling holes in coated components. Another advantage of an
embodiment is better control of airflow for coated components. Yet
another advantage is faster processing of coated components.
Another advantage of an embodiment is decreased time for cleaning
of cooling holes after components are coated or recoated. Yet
another advantage includes significant labor savings because no
drilling is required to clear cooling holes after coating.
[0067] Components of the present disclosure can be used in any
applications that undergo temperature changes, such as, but not
limited to, power generation systems which include, but are not
limited to gas turbines, steam turbines, jet turbines, and other
turbine assemblies. Moreover, embodiments of the present
disclosure, in comparison to coating methods not using one or more
of the features disclosed herein, increase coating efficiency,
provide apertures through a coating without post-coating clearing,
increase control of airflow for coated components, decrease coating
cost, decrease coating time, decreased time for cleaning apertures
after coating components, or a combination thereof.
[0068] The foregoing drawings show some of the processing
associated according to several embodiments of this disclosure. In
this regard, each drawing or block within a flow diagram of the
drawings represents a process associated with embodiments of the
method described. It should also be noted that in some alternative
implementations, the acts noted in the drawings or blocks may occur
out of the order noted in the figure or, for example, may in fact
be executed substantially concurrently or in the reverse order,
depending upon the act involved. Also, one of ordinary skill in the
art will recognize that additional blocks that describe the
processing may be added.
[0069] Approximating language, as used herein throughout the
specification and claims, may be applied to modify any quantitative
representation that could permissibly vary without resulting in a
change in the basic function to which it is related. Accordingly, a
value modified by a term or terms, such as "about," "approximately"
and "substantially," are not to be limited to the precise value
specified. In at least some instances, the approximating language
may correspond to the precision of an instrument for measuring the
value. Here and throughout the specification and claims, range
limitations may be combined and/or interchanged; such ranges are
identified and include all the sub-ranges contained therein unless
context or language indicates otherwise. "Approximately" as applied
to a particular value of a range applies to both end values, and
unless otherwise dependent on the precision of the instrument
measuring the value, may indicate +/-10% of the stated
value(s).
[0070] The corresponding structures, materials, acts, and
equivalents of all means or step plus function elements in the
claims below are intended to include any structure, material, or
act for performing the function in combination with other claimed
elements as specifically claimed. The description of the present
disclosure has been presented for purposes of illustration and
description but is not intended to be exhaustive or limited to the
disclosure in the form disclosed. Many modifications and variations
will be apparent to those of ordinary skill in the art without
departing from the scope and spirit of the disclosure. The
embodiment was chosen and described in order to best explain the
principles of the disclosure and the practical application, and to
enable others of ordinary skill in the art to understand the
disclosure for various embodiments with various modifications as
are suited to the particular use contemplated.
* * * * *