Classifications

• • C—CHEMISTRY; METALLURGY
  • C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
  • C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
  • C23C4/00—Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge
  • C23C4/02—Pretreatment of the material to be coated, e.g. for coating on selected surface areas
• • C—CHEMISTRY; METALLURGY
  • C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
  • C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
  • C23C4/00—Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge
  • C23C4/01—Selective coating, e.g. pattern coating, without pre-treatment of the material to be coated
• • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
  • F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
  • F01D—NON-POSITIVE DISPLACEMENT MACHINES OR ENGINES, e.g. STEAM TURBINES
  • F01D5/00—Blades; Blade-carrying members; Heating, heat-insulating, cooling or antivibration means on the blades or the members
  • F01D5/12—Blades
  • F01D5/28—Selecting particular materials; Particular measures relating thereto; Measures against erosion or corrosion
  • F01D5/288—Protective coatings for blades
• • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
  • F05—INDEXING SCHEMES RELATING TO ENGINES OR PUMPS IN VARIOUS SUBCLASSES OF CLASSES F01-F04
  • F05D—INDEXING SCHEME FOR ASPECTS RELATING TO NON-POSITIVE-DISPLACEMENT MACHINES OR ENGINES, GAS-TURBINES OR JET-PROPULSION PLANTS
  • F05D2300/00—Materials; Properties thereof
  • F05D2300/60—Properties or characteristics given to material by treatment or manufacturing
  • F05D2300/611—Coating

Definitions

• Embodiments of the subject matter disclosed herein relate to masking systems. Other embodiments relate to to pressure masking systems for cleaning articles with passageways or for coating articles with passageways.
• gas turbine engines such as aircraft engines for example
• air is drawn into the front of the engine, compressed by a shaft-mounted rotary-type compressor, and mixed with fuel.
• the mixture is burned, and the hot exhaust gases are passed through a turbine mounted on a shaft.
• the flow of gas turns the turbine, which turns the shaft and drives the compressor and fan.
• the hot exhaust gases flow from the back of the engine, driving it and the aircraft forward.
• the temperatures of combustion gases may exceed 3000°F (about 1650°C), considerably higher than the melting temperatures of the metal parts of the engine which are in contact with these gases. Operation of these engines at gas temperatures that are above the metal part melting temperatures is a well-established art, and depends in part on supplying a cooling air to the outer surfaces of the metal parts through various methods.
• the metal parts of these engines that are particularly subject to high temperatures, and thus require particular attention with respect to cooling, are the metal parts forming combustors and parts located aft of the combustor.
• the metal temperatures can be maintained below melting levels by using passageways such as cooling holes incorporated into some engine components.
• a thermal barrier coatings may also be applied to the component by a pressure coating process (e.g., a thermal spray process).
• a pressure coating process e.g., a thermal spray process
• the thermal spray process and other cleaning processes e.g., grit blasting, shot peening, water jet washing
• overspray that partially or completely blocks the component's cooling holes.
• present coating e.g., thermal spray
• cleaning processes involve a multi-step, highly labor intensive process of applying a partial layer of TBC coating, allowing the component and the TBC to sufficiently cool to a temperature at which the component can easily be handled, removing the component from an application fixture on which the thermal spraying takes place, and removing any masking, which is then followed by separately removing the well-cooled, solidified coating from the cooling holes using a water jet or other cleaning methods.
• a fraction of the desired TBC thickness is applied prior to cleaning. As a result, the entire process must typically be repeated several times until the desired TBC thickness is reached.
• An embodiment relates to a method of pressure cleaning or pressure coating a target surface of an article comprising one or more passageways.
• the method comprises fluidly connecting a pressure masker comprising pressurized masking fluid to a first side of at least one passageway, and passing the pressurized masking fluid through the at least one passageway from the first side to a second side comprising the target surface.
• the method further comprises cleaning the target surface or coating the target surface by projecting a cleaning material or a coating material, respectively, towards the target surface.
• the pressurized masking fluid passing through the at least one passageway prevents the cleaning material or the coating material, as applicable, from permanently altering a cross sectional area of the at least one passageway.
• the pressurized masking system comprises a pressure masker configured to fluidly connect to a first side of at least one passageway of the article and to pass a pressurized masking fluid through the passageway from the first side to a second side.
• the second side comprises the target surface.
• the system further comprises either a part cleaner configured to project a cleaning material towards the target surface, or a part coater configured to project a coating material towards the target surface.
• the pressurized masking fluid prevents the cleaning material or the coating material, respectively, from permanently altering a cross sectional area of the at least one passageway.
• a method of pressure cleaning a target surface of an article comprising one or more passageways includes fluidly connecting a pressure masker comprising pressurized masking fluid to a first side of at least one passageway, passing the pressurized masking fluid through the at least one passageway from the first side to a second side comprising the target surface, and, cleaning the target surface using a cleaning material, wherein the pressurized masking fluid passing through the at least one passageway prevents the cleaning material from permanently altering a cross sectional area of the at least one passageway.
• a pressurized masking system for cleaning a target surface of an article comprising passageways.
• the pressurized masking system includes a pressure masker that fluidly connects to a first side of at least one passageway of the article and passes a pressurized masking fluid through the passageway from the first side to a second side, wherein the second side comprises the target surface.
• the pressurized masking system further includes a part cleaner that projects a cleaning material towards the target surface, wherein the pressurized masking fluid prevents the cleaning material from permanently altering a cross sectional area of the at least one passageway.
• a method of pressure coating a target surface of an article comprising one or more passageways includes fluidly connecting a pressure masker comprising pressurized masking fluid to a first side of at least one passageway, passing the pressurized masking fluid through the at least one passageway from the first side to a second side comprising the target surface, and, coating the target surface using a coating material, wherein the pressurized masking fluid passing through the at least one passageway prevents the coating material from permanently altering a cross sectional area of the at least one passageway.
• a pressurized masking system for coating a target surface of an article comprising passageways.
• the pressurized masking system includes a pressure masker that fluidly connects to a first side of at least one passageway of the article and passes a pressurized masking fluid through the passageway from the first side to a second side, wherein the second side comprises the target surface.
• the pressurized masking system further includes a part coater that projects a coating material towards the target surface, wherein the pressurized masking fluid prevents the coating material from permanently altering a cross sectional area of the at least one passageway.
• FIG. 1 is a schematic illustrated of a pressure masking system according to one or more embodiments shown or described herein;
• FIG. 2 is a perspective view of a pressure masking system according to one or more embodiments shown or described herein;
• FIG. 3 is a perspective view of another pressure masking system according to one or more embodiments shown or described herein;
• FIG. 4 is a flowchart illustrating a method of pressure cleaning an article using a pressure masking system according to one or more embodiments shown or described herein;
• FIG. 5 is a schematic illustrated of a pressure masking system according to one or more embodiments shown or described herein;
• FIG. 6 is a perspective view of a pressure masking system according to one or more embodiments shown or described herein;
• FIG. 7 is a perspective view of another pressure masking system according to one or more embodiments shown or described herein; and,
• FIG. 8 is a flowchart illustrating a method of pressure coating an article using a pressure masking system according to one or more embodiments shown or described herein.
• Pressurized masking systems disclosed herein generally comprise a pressure masker, and either a part cleaner to clean the target surface of an article comprising passageways or a part coater to coat the target surface of the article comprising passageways. While the part cleaner (or the part coater) projects cleaning material (or coating material) towards the target surface, pressurized masking fluid is fluidly connected to the passageways and passed there through to prevent the permanent altering of a cross sectional area of the passageways by the cleaning or coating material. Pressurized masking systems, and methods of pressure cleaning or pressure coating a target surface of an article, will be discussed in more detail herein.
• a pressurized masking system 100 comprising a part cleaner 20 and a pressure masker 30 for cleaning an article 10.
• the article 10 comprises one or more passageways 12 passing through the article 10 from a first side 18 to a second side 19.
• the article 10 can comprise a variety of different parts such as a combustor liner or other component of a gas turbine engine.
• the article 10 can comprise a turbine component such as a hot gas path component or a combustion component.
• the passageways 12 can comprise any passage through the article 10 (passing from the first side 18 to the second side 19) that is intended to remain open (such that air can pass through) when the article 10 is in use.
• the passageways 12 may comprise cooling holes.
• the second side 19 of the article 10 comprises a target surface 11 that is to be cleaned.
• the target surface 11 may be cleaned prior to first use, during routine or repair maintenance, or as otherwise necessary depending on the life of the article 10.
• cleaned refers to stripping, washing and/or treating the target surface such as through grit blasting, shot peening, water jet washing or the like as will become appreciated herein.
• the target surface 11 of the article 10 may comprise a coating 22 or other debris that is to be removed prior to applying a fresh coating.
• the target surface 11 of the article 10 may have or will have a thermal barrier coating ("TBC") disposed thereon.
• TBC thermal barrier coating
• the TBC can comprise one or more layers of metal and/or ceramic coating material applied to the target surface 11 of the article 10 to impede the transfer of heat from hot combustion gases to the article 10, thus insulating the component from the hot combustion gas.
• the presence of the TBC on the surface permits the combustion gas to be hotter than would otherwise be possible with the particular material and fabrication process of the component.
• Any suitable composition of TBC may be applied.
• the TBC can comprise a bond layer of MCrAlY, wherein M is preferably Ni, Co, or a combination thereof, followed by a layer of yttria stabilized zirconia (YSZ).
• the article 10 may be disposed on a support stand 15 prior to or during the pressure cleaning as will become appreciated herein.
• the support stand 15 may be stationary or mobile (e.g., rotatable) and position the article 10 relative to the part cleaner 20 and the pressure masker 30 when cleaning the target surface 11 of the article 10.
• the pressurized masking system 100 further comprises the part cleaner 20.
• the part cleaner 20 comprises any device that projects a cleaning material 25 towards the target surface 11 of the article 10.
• the part cleaner 20 can comprise a grit blaster.
• the cleaning material 25 can comprise pressurized air with aluminum oxide, walnut shells, dry ice, charcoal, or any other particulates dispersed therein.
• the part cleaner 20 can comprise a shot peening device.
• the cleaning material 25 can comprise pressurized air with metallic, glass or ceramic particles dispersed therein.
• the part cleaner 20 may comprise a pressure washer.
• the cleaning material 25 may comprise water with or without an additional abrasive material.
• the part cleaner 20 may be disposed at any position relative to the article 10 that allows for the cleaning of the target surface 11.
• the article 10 may be disposed on a support stand 15 adjacent the part cleaner 20.
• the support stand 15 may then be able to rotate or otherwise displace the article 10 with respect to the part cleaner 20 and/or the part cleaner 20 may be able to articulate with respect to the article 10.
• the part cleaner 20 may then be used to project the cleaning material 25 towards the target surface 11 of the article 10.
• some of the cleaning material 25 may enter one or more of the passageways 12 from the second side 19 of the article 10.
• some of the cleaning material 25, and more particularly any particulates e.g., sand, shot, abrasives, etc.
• the part cleaner 20 may be used for a variety of applications to clean the target surface 11 of the article 10.
• the part cleaner 20 may be used to remove dirt or other contaminants prior to applying a new coat.
• the part cleaner 20 may be used to remove a previously applied coating that has since been worn and/or damaged.
• the part cleaner 20 may be used to remove part or all of a TBC on the target surface 11 before reapplying or rejuvenating the TBC.
• the part cleaner 20 may be used to remove one or more metallic coatings, contamination layers (e.g., rust, dirt, oxidation, etc.), diffused layers or other unwanted layers. While specific embodiments have been presented herein, it should be appreciated that these are exemplary only and any other application of the part cleaner 20 as part of the pressurized masking system 100 may also be realized.
• the pressurized masking system 100 further comprises a pressure masker 30.
• the pressure masker 30 comprises a fluid connection 31 that fluidly connects a source of masking fluid 35 to at least one passageway 12 of the article 10.
• fluid connection refers to a connection that allows the pressurized masking fluid 35 to pass from the pressure masker 30 to the passageway 12 with negligent loss to the outside environment.
• the fluid connection can comprise, for example, flexible tubes, hoses, pipes or any other conduit that directs the passage of the pressurized masking fluid 35 to the one or more passageways 12.
• the fluid connection 31 may comprise a tube that directly connects the output of the pressure masker 30 to the first side 18 of the passageway 12.
• the fluid connection 31 may comprise a single tube between the pressure masker 30 and a single passageway 12 (such as that illustrated in FIG. 2).
• the fluid connection may comprise a single tube leaving the pressure masker 30 that breaks off into segments that connect to a plurality of passageways 12 (such as that illustrated in FIG. 1).
• the fluid connection 31 may comprise a plurality of tubes leaving the pressure masker 30 that connects to a single or a plurality of passageways 12.
• the fluid connection 31 may comprise a plurality of channels of similar or dissimilar pressurized masking fluids 35 that connect to two or more passageways.
• the plurality of channels may comprise different pressures, temperatures, directions or mixtures of pressurized masking fluids 35. It should be appreciated that any other configuration that provides a fluid connection 31 between the pressure masker 30 and one or more passageways 12 may alternatively or additionally be realized.
• the fluid connection 31 may comprise a multi-outlet manifold connection 40 comprising an internal passage 41 that can receive pressurized masking fluid 35 from the pressure masker 30 and fluidly distribute it to one or more passageways.
• the multi-outlet manifold connection 40 can thereby attach directly to the first side 18 of the article 10 and distribute the pressurized masking fluid 35 to a wide area about the article 10. Any passageways 12 within that area will thereby have pressurized masking fluid 35 fluidly pass there through.
• the pressurized masking fluid 35 can comprise any medium that can pass through the passageway 12 with a positive energy and prevent the permanent altering of a cross sectional area of the at least one passageway by the cleaning material 25 (or particulates thereof).
• "prevent the permanent altering of a cross sectional area" refers to removing and/or preventing substantially all of the cleaning material 25 that may enter the passageway 12 so that the cross sectional area of the passageway is not substantially reduced by a permanent obstruction 32 or increased due to erosion, deformation or the like.
• obstructions that would permanently alter the cross sectional area of the passageway 12 include, for example, large particulates lodged against a wall, a clumping of cleaning material 25 or the like.
• the pressurized masking fluid 35 may thereby comprise any material that can be forced through the one or more passageways 12 at a masking pressure to impact on and remove potential obstructions 32 from the cleaning material 25 that would alter the cross sectional area.
• the pressurized masking fluid 35 may comprise a gas such as inert gas or nitrogen.
• a gas such as inert gas or nitrogen.
• the pressurized masking fluid 35 may comprise water with or without abrasives distributed therein.
• the part cleaner 20 comprises a water jet or similar device. While specific embodiments of pressurized masking fluid and part cleaners have been presented herein, it should be appreciated that additional and alternative pressurized masking fluids and part cleaners may also be realized.
• the pressurized masking fluid 35 may comprise a masking pressure that is greater than, equal to, or less than a cleaning pressure of the cleaning material so long as the pressurized masking fluid 35 has enough energy to remove obstructions 32 from the passageways 12.
• the masking pressure may comprise a negative pressure (such as via a vacuum or suction element on the second side 19 of the article 10 such that the negative pressure pulls the pressurized masking fluid 35 through the passageway 12.
• the masking pressure may comprise a variable pressure that fluctuates during the masking process.
• the pressure masker 30 thereby passes the pressurized masking fluid 35 through the at least one passageway 12 at a masking pressure from the first side 18 to the second side 19 (wherein the second side 19 comprises the target surface 11 of the article 10 that is to be cleaned).
• the part cleaner cleans the target surface 11 of the article 10 by projecting cleaning material 25 towards the target surface.
• some of the cleaning material 25 may enter one or more passageways 12 and form one or more obstructions 32.
• the obstructions 32 may comprise a grouping of particulates from the cleaning material that would decrease the cross sectional area of the passageway 12 and reduce the amount of air that could flow there through.
• the pressurized masking fluid 35 will contact the obstruction 32 and push it back out of the passageway 12.
• the pressurized masking fluid 35 may prevent any obstructions 32 from even entering the passageways 12 via the pressurized masking fluid 35 exiting the passageway 12 on the second side 19 of the article 10.
• a method 200 for pressure cleaning a target surface 11 of an article 10 comprising one or more passageways 12.
• the method 200 first comprises fluidly connecting the pressure masker 30 to a first side 18 of at least one passageway 12 of the article 10 in step 210.
• the fluid connection 31 may comprise a variety of configurations and may connect any type of pressure masker 30 to any number of passageways 12.
• the pressure masker 30 then passes pressurized masking fluid 35 through the at least one passageway from the first side 18 to the second side 19 in step 220.
• the part cleaner 20 cleans the target surface 11 on the second side 19 of the article 10 by projecting cleaning material 25 towards the target surface 11 in step 230.
• passing pressurized masking fluid 35 through the at least one passageway 12 in step 220 and cleaning the target surface 11 in step 230 may start and end simultaneously in or with relative delay.
• the pressurized masking fluid 35 may be passing through the passageway 12 in step 20 prior to the initiation of cleaning the target surface 11 in step 230.
• Such embodiments may prevent a buildup of obstructions 32 prior to activation of the pressure masker 30.
• the pressurized masking fluid 35 may continue to pass through the passageway 12 in step 220 after the article 10 is cleaned in step 230. Such embodiments may help ensure any obstacles 32 remaining in the passageways 12 after cleaning is complete in step 230 are still removed by the pressurized masking fluid 35.
• FIGS. 1-4 are directed to embodiments where a pressurized masking system comprises a pressure masker and a part cleaner to clean the target surface of an article comprising passageways
• FIGS. 5-8 are directed to embodiments where the pressurized masking system comprises the pressure masker and a part coater to coat the target surface of the article comprising passageways.
• a pressurized masking system 1000 is illustrated comprising a part coater 1020 and a pressure masker 1030 for coating an article 1010.
• the article 1010 comprises one or more passageways 1012 passing through the article 1010 from a first side 1018 to a second side 1019.
• the article 1010 can comprise a variety of different parts such as a combustor liner or other component of a gas turbine engine.
• the article 1010 can comprise a turbine component such as a hot gas path component or a combustion component.
• the passageways 1012 can comprise any passage through the article 1010 (passing from the first side 1018 to the second side 1019) that is intended to remain open (such that air can pass through) when the article 1010 is in use.
• the passageways 1012 may comprise cooling holes.
• the second side 1019 of the article 1010 comprises a target surface 1011 that is to be coated.
• the target surface 1011 may be coated prior to first use, during routine or repair maintenance, or as otherwise necessary depending on the life of the article 1010.
• coated refers to at least partially applying a new material to a surface such as through the use of a thermal spray gun or the like as will become appreciated herein.
• the target surface 1011 of the article 1010 may have a TBC coated thereon prior to operation.
• the TBC can comprise one or more layers of metal and/or ceramic coating material applied to the target surface 1011 of the article 1010 to impede the transfer of heat from hot combustion gases to the article 1010, thus insulating the component from the hot combustion gas.
• the presence of the TBC on the surface permits the combustion gas to be hotter than would otherwise be possible with the particular material and fabrication process of the component.
• Any suitable composition of TBC may be applied.
• the TBC can comprise a bond layer of MCrAlY, wherein M is preferably Ni, Co, or a combination thereof, followed by a layer of yttria stabilized zirconia (YSZ).
• the article 1010 may be disposed on a support stand 1015 prior to or during the pressure coating as will become appreciated herein.
• the support stand 1015 may be stationary or mobile (e.g., rotatable) and position the article 1010 relative to the part coater 1020 and the pressure masker 1030 when coating the target surface 1011 of the article 1010.
• the pressurized masking system 1000 further comprises the part coater 1020.
• the part coater 1020 comprises any device that projects a coating material 1025 towards the target surface 1011 of the article 1010.
• the part coater 1020 can comprise a thermal spray gun.
• the coating material 1025 can comprise pressurized gas or a pressurized liquid (e.g., as water), as a carrier or otherwise.
• the part coater 1020 can comprise any other device that projects coating material 1025 towards the target surface 1011 of the article 1010.
• the part coater 1020 may be disposed at any position relative to the article 1010 that allows for the coating of the target surface 1011.
• the article 1010 may be disposed on a support stand 1015 adjacent the part coater 1020.
• the support stand 1015 may then be able to rotate or otherwise displace the article 1010 with respect to the part coater 1020 and/or the part coater 1020 may be able to articulate with respect to the article 1010.
• the part coater 1020 may then be used to project the coating material 1025 towards the target surface 1011 of the article 1010.
• some of the coating material 1025 may enter one or more of the passageways 1012 from the second side
• some of the coating material 1025 may potentially form obstructions 1032 in the one or more passageways 1012 if left unopposed.
• the part coater 1020 may be used for a variety of applications to coat the target surface 1011 of the article 1010.
• the part coater 1020 may be used to coat the target surface with a TBC as discussed above.
• the part coater 1020 may be used to apply a bond coat to the target surface 1011 for the subsequent application of a TBC or other coating.
• the part coater 1020 may be used to apply a paint coat to the target surface 1011.
• the part coater 1020 may be used to apply other coatings such as diffusion coatings, DVC TBC, HVOF or other adhesive boding coatings. While specific embodiments have been presented herein, it should be appreciated that these are exemplary only and any other application of the part coater
• the pressurized masking system 1000 further comprises a pressure masker 1030.
• the pressure masker 1030 comprises a fluid connection 1031 that fluidly connects a source of masking fluid 1035 to at least one passageway 1012 of the article 1010.
• fluid connection refers to a connection that allows the pressurized masking fluid 1035 to pass from the pressure masker 1030 to the passageway 1012 with negligent loss to the outside environment.
• the fluid connection can comprise, for example, flexible tubes, hoses, pipes or any other conduit that directs the passage of the pressurized masking fluid 1035 to the one or more passageways 1012.
• the fluid connection 1031 may comprise a tube that directly connects the output of the pressure masker 1030 to the first side 1018 of the passageway 1012.
• the fluid connection 1031 may comprise a single tube between the pressure masker 1030 and a single passageway 1012 (such as that illustrated in FIG. 6).
• the fluid connection may comprise a single tube leaving the pressure masker 1030 that breaks off into segments that connect to a plurality of passageways 1012 (such as that illustrated in FIG. 5).
• the fluid connection 1031 may comprise a plurality of tubes leaving the pressure masker 1030 that connects to a single or a plurality of passageways 1012.
• the fluid connection 1031 may comprise a plurality of channels of similar or dissimilar pressurized masking fluids 1035 that connect to two or more passageways.
• the plurality of channels may comprise different pressures, temperatures, directions or mixtures of pressurized masking fluids 1035. It should be appreciated that any other configuration that provides a fluid connection 1031 between the pressure masker 1030 and one or more passageways 1012 may alternatively or additionally be realized.
• the fluid connection 1031 may comprise a multi-outlet manifold connection 1040 comprising an internal passage 1041 that can receive pressurized masking fluid 1035 from the pressure masker 1030 and fluidly distribute it to one or more passageways.
• the multi-outlet manifold connection 1040 can thereby attach directly to the first side 1018 of the article 1010 and distribute the pressurized masking fluid 1035 to a wide area about the article 1010. Any passageways 1012 within that area will thereby have pressurized masking fluid 1035 fluidly pass there through.
• the pressurized masking fluid 1035 can comprise any medium that can pass through the passageway 1012 with a positive energy and prevent the permanent altering of a cross sectional area of the at least one passageway by the coating material 1025 (or particulates thereof).
• "prevent the permanent altering of a cross sectional area" (and variants thereof), in relation to a coating operation refers to removing and/or preventing substantially all of the coating material 1025 that may enter the passageway 1012 so that the cross sectional area of the passageway is not substantially reduced by a permanent obstruction 1032 or increased due to erosion, deformation or the like.
• a thin coating of the interior walls directly proximate the second side 1019 of the coating material 1025 is not considered to permanently alter the cross sectional area of the passageway 1012 as any such reduction would be relatively minimal and not noticeably affect the flow of air through the passageway 1012 during operation.
• obstructions that would permanently alter the cross sectional area of the passageway 1012 include, for example, large particulates lodged against a wall, a clumping of coating material 1025 or the like.
• the pressurized masking fluid 1035 may thereby comprise any material that can be forced through the one or more passageways 1012 at a masking pressure to impact on and remove potential obstructions 1032 from the coating material 1025 that would alter the cross sectional area.
• the pressurized masking fluid 1035 may comprise a gas such as inert gas or nitrogen.
• the pressurized masking fluid 1035 may comprise water with or without abrasives distributed therein. While specific embodiments of pressurized masking fluid 1035 and part coaters have been presented herein, it should be appreciated that additional and alternative pressurized masking fluids and part coaters may also be realized.
• the pressurized masking fluid 1035 may comprise a masking pressure that is greater than, equal to, or less than a coating pressure of the coating material 1025 so long as the pressurized masking fluid 1035 has enough energy to remove obstructions 1032 from the passageways 1012.
• the masking pressure may comprise a positive pressure such that the positive pressure pushes the pressurized masking fluid 1035 through the passageway 1012.
• the masking pressure may comprise a negative pressure (such as via a vacuum or suction element on the second side 1019 of the article 1010 such that the negative pressure pulls the pressurized masking fluid 1035 through the passageway 1012.
• the masking pressure may comprise a variable pressure that fluctuates during the masking process.
• the pressure masker 1030 thereby passes the pressurized masking fluid 1035 through the at least one passageway 1012 at a masking pressure from the first side 1018 to the second side 1019 (wherein the second side 1019 comprises the target surface 1011 of the article 1010 that is to be coated).
• the part coater coats the target surface 1011 of the article 1010 by projecting coating material 1025 towards the target surface.
• some of the coating material 1025 may enter one or more passageways 1012 and form one or more obstructions 1032.
• the obstructions 1032 may comprise a grouping of particulates from the coating material that would decrease the cross sectional area of the passageway 1012 and reduce the amount of air that could flow there through.
• the pressurized masking fluid 1035 will contact the obstruction 1032 and push it back out of the passageway 1012.
• the pressurized masking fluid 1035 may prevent any obstructions 1032 from even entering the passageways 1012 via the pressurized masking fluid 1035 exiting the passageway 1012 on the second side 1019 of the article 1010.
• a method 2000 for pressure coating a target surface 1011 of an article 1010 comprising one or more passageways 1012.
• the method 2000 first comprises fluidly connecting the pressure masker 1030 to a first side 1018 of at least one passageway 1012 of the article 1010 in step 2010.
• the fluid connection 1031 may comprise a variety of configurations and may connect any type of pressure masker 1030 to any number of passageways 1012.
• the pressure masker 1030 then passes pressurized masking fluid 1035 through the at least one passageway from the first side 1018 to the second side 1019 in step 2020.
• the part coater 1020 coats the target surface 1011 on the second side 1019 of the article 1010 by projecting coating material 1025 towards the target surface 1011 in step 2030.
• passing pressurized masking fluid 1035 through the at least one passageway 1012 in step 2020 and coating the target surface 1011 in step 2030 may start and end simultaneously in or with relative delay.
• the pressurized masking fluid 1035 may be passing through the passageway 1012 in step 1020 prior to the initiation of coating the target surface 1011 in step 2030.
• Such embodiments may prevent a buildup of obstructions 1032 prior to activation of the pressure masker 1030.
• the pressurized masking fluid 1035 may continue to pass through the passageway 1012 in step 2020 after the article 1010 is coated in step 2030. Such embodiments may help ensure any obstacles 1032 remaining in the passageways 1012 after coating is complete in step 2030 are still removed by the pressurized masking fluid 1035.
• Another embodiment relates to a method of pressure cleaning or pressure coating a target surface of an article comprising one or more passageways.
• the method comprises fluidly connecting a pressure masker comprising pressurized masking fluid to a first side of at least one passageway, and passing the pressurized masking fluid through the at least one passageway from the first side to a second side comprising the target surface.
• the method further comprises cleaning the target surface or coating the target surface by projecting a cleaning material or a coating material, respectively, towards the target surface.
• the pressurized masking fluid passing through the at least one passageway prevents the cleaning material or the coating material, as applicable, from permanently altering a cross sectional area of the at least one passageway.
• the fluid connection comprises a multi-outlet manifold connection that connects to the first side and comprises an internal passage.
• the internal passage receives the pressurized masking fluid and fluidly distributes it to one or more passageways.
• the pressurized masking fluid comprises a gas, e.g., nitrogen.
• the method comprises cleaning the target surface by projecting the cleaning material towards the target surface.
• a grit blaster or shot peening device cleans the target surface using the cleaning material.
• the passageway comprises a cooling hole.
• the pressurized masking fluid comprises a liquid.
• the liquid comprises abrasives.
• the method comprises cleaning the target surface by projecting the cleaning material towards the target surface. A water jet cleans the target surface using the cleaning material.
• the method comprises cleaning the target surface by projecting the cleaning material towards the target surface.
• the pressurized masking fluid continues to pass through the at least one passageway after cleaning the target surface is complete.
• the method comprises cleaning the target surface by projecting the cleaning material towards the target surface.
• the pressurized masking fluid passes through the at least one passageway at a masking pressure that is less than a cleaning pressure of the cleaning material.
• the method comprises coating the target surface by projecting the coating material towards the target surface.
• the coating material comprises MCrAlY, and wherein M is Ni or Co.
• the method comprises coating the target surface by projecting the coating material towards the target surface.
• the coating material comprises yttria stabilized zirconia.
• the method comprises coating the target surface by projecting the coating material towards the target surface.
• a thermal spray gun projects the coating material to coat the target surface.
• the method comprises coating the target surface by projecting the coating material towards the target surface.
• the pressurized masking fluid continues to pass through the at least one passageway after coating the target surface is complete.
• the method comprises comprising coating the target surface by projecting the coating material towards the target surface.
• the pressurized masking fluid passes through the at least one passageway at a masking pressure that is less than a coating pressure of the coating material.
• Another embodiment relates to a pressurized masking system for cleaning or coating a target surface of an article comprising passageways.
• the pressurized masking system comprises a pressure masker configured to fluidly connect to a first side of at least one passageway of the article and to pass a pressurized masking fluid through the passageway from the first side to a second side.
• the second side comprises the target surface.
• the system further comprises either a part cleaner configured to project a cleaning material towards the target surface, or a part coater configured to project a coating material towards the target surface.
• the pressurized masking fluid prevents the cleaning material or the coating material, respectively, from permanently altering a cross sectional area of the at least one passageway.
• the fluid connection comprises a multi-outlet manifold connection that connects to the first side of the article and comprises an internal passage.
• the internal passage receives the pressurized masking fluid and fluidly distributes it to one or more passageways.
• the pressurized masking fluid comprises a gas or a liquid, e.g., the liquid comprising abrasives.
• the part cleaner comprises a grit blaster.
• the part cleaner comprises a shot peening device.
• the part cleaner comprises a water jet.
• the pressurized masking fluid passes through the at least one passageway at a masking pressure that is less than a cleaning pressure of the cleaning material.
• the target surface comprises a thermal barrier coating.
• the at least one passageway comprises a cooling hole.
• the coating material comprises MCrAlY, wherein M is Ni or Co.
• the coating material comprises yttria stabilized zirconia.
• the part coater configured to project the coating material towards the target surface
• the part coater comprises a thermal spray gun
• the pressurized masking fluid passes through the at least one passageway at a masking pressure that is less than a coating pressure of the coating material.
• the article comprises a turbine component.
• pressurized masking systems may be used to clean or coat the target surface of an article while preventing the permanent altering of a cross sectional area of one or more passageways.
• the use of a fluid connection between the pressure masker and the one or more passageways can prevent the need for physical masking barriers such as tape, wax, or the like, potentially providing a more efficient cleaning or coating system.

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• Chemical & Material Sciences (AREA)
• Engineering & Computer Science (AREA)
• Mechanical Engineering (AREA)
• Plasma & Fusion (AREA)
• Chemical Kinetics & Catalysis (AREA)
• Materials Engineering (AREA)
• Physics & Mathematics (AREA)
• Metallurgy (AREA)
• Organic Chemistry (AREA)
• Details Or Accessories Of Spraying Plant Or Apparatus (AREA)
• Application Of Or Painting With Fluid Materials (AREA)
• Cleaning In General (AREA)
• Turbine Rotor Nozzle Sealing (AREA)
• Coating By Spraying Or Casting (AREA)

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• 2012
  • 2012-12-27 JP JP2014550460A patent/JP6220346B2/ja active Active
  • 2012-12-27 EP EP12818755.6A patent/EP2798095B1/de active Active
  • 2012-12-27 WO PCT/US2012/071798 patent/WO2013101921A2/en active Application Filing
  • 2012-12-27 CN CN201280065042.2A patent/CN104024465A/zh active Pending

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