EP3184735A2 - Local repair or remanufacture of polymeric erosion coatings - Google Patents
Local repair or remanufacture of polymeric erosion coatings Download PDFInfo
- Publication number
- EP3184735A2 EP3184735A2 EP16204796.3A EP16204796A EP3184735A2 EP 3184735 A2 EP3184735 A2 EP 3184735A2 EP 16204796 A EP16204796 A EP 16204796A EP 3184735 A2 EP3184735 A2 EP 3184735A2
- Authority
- EP
- European Patent Office
- Prior art keywords
- sol
- component
- gel layer
- recited
- layer
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
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Classifications
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- 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
- C23C18/00—Chemical coating by decomposition of either liquid compounds or solutions of the coating forming compounds, without leaving reaction products of surface material in the coating; Contact plating
- C23C18/02—Chemical coating by decomposition of either liquid compounds or solutions of the coating forming compounds, without leaving reaction products of surface material in the coating; Contact plating by thermal decomposition
- C23C18/12—Chemical coating by decomposition of either liquid compounds or solutions of the coating forming compounds, without leaving reaction products of surface material in the coating; Contact plating by thermal decomposition characterised by the deposition of inorganic material other than metallic material
- C23C18/125—Process of deposition of the inorganic material
- C23C18/1254—Sol or sol-gel processing
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- 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
- F01D5/005—Repairing methods or devices
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- 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
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- 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
- F05D2220/00—Application
- F05D2220/30—Application in turbines
- F05D2220/36—Application in turbines specially adapted for the fan of turbofan engines
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- 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
- F05D2300/40—Organic materials
- F05D2300/43—Synthetic polymers, e.g. plastics; Rubber
Definitions
- the present disclosure relates generally to a remanufactures process and, more particularly, to a repair process for aluminum fan blades.
- Gas turbine engines such as those that power modern commercial and military aircraft, generally include a fan section, a compressor section to pressurize an airflow, a combustor section to burn a hydrocarbon fuel in the presence of the pressurized air, and a turbine section to extract energy from the resultant combustion gases.
- the fan section often includes aluminum fan blades designed with a multi-layer polyurethane erosion coating to protect both sides of the airfoil from operational erosion and subsequent corrosion.
- the erosion coatings sustain erosion, FOD and local damage in service, but there is only minimal repair capability for these coatings.
- a method according to one disclosed non-limiting embodiment of the present disclosure e.g. a method for repairing a component or a multi-layer polyurethane erosion coating can include applying a Sol-Gel layer onto a substrate and applying an erosion coating layer over the Sol-Gel layer.
- a further embodiment of the present disclosure may include, wherein the method is applied to a local area.
- a further embodiment of the present disclosure may include, wherein the method provides for a local repair to a fan blade.
- a further embodiment of the present disclosure may include applying a paint primer to the Sol-Gel layer prior to applying the erosion coating layer.
- a component according to one disclosed non-limiting embodiment of the present disclosure can include a local area with a Sol-Gel layer over an aluminum substrate.
- a further embodiment of the present disclosure may include an erosion coating is over the Sol-Gel layer.
- a further embodiment of the present disclosure may include a paint primer between the Sol-Gel layer and the erosion coating layer.
- a further embodiment of the present disclosure may include, wherein the component is a fan blade.
- a further embodiment of the present disclosure may include, wherein the paint primer is a corrosion inhibiting paint primer.
- a further embodiment of the present disclosure may include, wherein the coating is a multi-layer polyurethane erosion coating
- a further embodiment of the present disclosure may include a component obtained by the methods as herein described.
- Figure 1 schematically illustrates a general perspective view of an exemplary component 20, e.g., a fan blade with a multi-layer polyurethane erosion coating for a gas turbine engine.
- exemplary component 20 e.g., a fan blade with a multi-layer polyurethane erosion coating for a gas turbine engine.
- a cross-section of the component 20 is illustrated for an aluminum substrate 30 such as a 2000, 6000, or 7000 series aluminum with a multi-layer coating 35.
- the coating 35 includes a phosphoric acid anodizer layer 40, an epoxy bond primer 50 as a corrosion inhibitor, a paint primer 60, and an erosion coating 70 such as a urethane as the outer layer. It should be appreciated that various materials may be utilized in accords with this layer structure.
- a local repair 100 for the component 20 may be performed on an airflow surface. That is, the local repair of damage may be performed in response to damage within the polyurethane coating stack up on the aluminum substrate 30.
- the local repair 100 may be initiated by abrading down to the aluminum substrate 30 or for damage that has reached down to the aluminum substrate 30.
- the polyurethane coating stack adjacent to the damage may be abraded, feathered or otherwise prepared and cleaned with, for example aluminum oxide and an acetone wipe.
- a Sol-Gel layer 110 is applied over the aluminum substrate 30 to react with the aluminum substrate 30 and thereby provide a stable surface.
- the Sol-Gel layer 110 may be provided with a 1hour room temperature cure.
- the Sol-Gel layer 110 process involves conversion of monomers into a colloidal solution (sol) that acts as the precursor for an integrated network (or gel) of either discrete particles or network polymers.
- the Sol-Gel layer 110 does not adversely react or effect adjacent coatings layers 40-70 such that masking is not otherwise required.
- the paint primer 60 is applied over the Sol-Gel layer 110.
- the Sol-Gel layer 110 significantly improves the adhesion of paint primers within the coating stack up.
- the erosion coating 70 is applied over the paint primer 60 to finalize the local repair 100.
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- Chemical & Material Sciences (AREA)
- Engineering & Computer Science (AREA)
- Mechanical Engineering (AREA)
- General Engineering & Computer Science (AREA)
- Materials Engineering (AREA)
- Physics & Mathematics (AREA)
- Chemical Kinetics & Catalysis (AREA)
- General Chemical & Material Sciences (AREA)
- Thermal Sciences (AREA)
- Inorganic Chemistry (AREA)
- Metallurgy (AREA)
- Organic Chemistry (AREA)
- Dispersion Chemistry (AREA)
- Application Of Or Painting With Fluid Materials (AREA)
- Structures Of Non-Positive Displacement Pumps (AREA)
Abstract
Description
- The present disclosure relates generally to a remanufactures process and, more particularly, to a repair process for aluminum fan blades.
- Gas turbine engines, such as those that power modern commercial and military aircraft, generally include a fan section, a compressor section to pressurize an airflow, a combustor section to burn a hydrocarbon fuel in the presence of the pressurized air, and a turbine section to extract energy from the resultant combustion gases.
- The fan section often includes aluminum fan blades designed with a multi-layer polyurethane erosion coating to protect both sides of the airfoil from operational erosion and subsequent corrosion. The erosion coatings sustain erosion, FOD and local damage in service, but there is only minimal repair capability for these coatings.
- A method according to one disclosed non-limiting embodiment of the present disclosure e.g. a method for repairing a component or a multi-layer polyurethane erosion coating can include applying a Sol-Gel layer onto a substrate and applying an erosion coating layer over the Sol-Gel layer.
- A further embodiment of the present disclosure may include, wherein the method is applied to a local area.
- A further embodiment of the present disclosure may include, wherein the method provides for a local repair to a fan blade.
- A further embodiment of the present disclosure may include applying a paint primer to the Sol-Gel layer prior to applying the erosion coating layer.
- A component according to one disclosed non-limiting embodiment of the present disclosure can include a local area with a Sol-Gel layer over an aluminum substrate.
- A further embodiment of the present disclosure may include an erosion coating is over the Sol-Gel layer.
- A further embodiment of the present disclosure may include a paint primer between the Sol-Gel layer and the erosion coating layer.
- A further embodiment of the present disclosure may include, wherein the component is a fan blade.
- A further embodiment of the present disclosure may include, wherein the paint primer is a corrosion inhibiting paint primer.
- A further embodiment of the present disclosure may include, wherein the coating is a multi-layer polyurethane erosion coating
- A further embodiment of the present disclosure may include a component obtained by the methods as herein described.
- The foregoing features and elements may be combined in various combinations without exclusivity, unless expressly indicated otherwise. These features and elements as well as the operation of the invention will become more apparent in light of the following description and the accompanying drawings. It should be understood, however, the following description and drawings are intended to be exemplary in nature and non-limiting.
- Various features will become apparent to those skilled in the art from the following detailed description of the disclosed non-limiting embodiment. The drawings that accompany the detailed description can be briefly described as follows:
-
Figure 1 is a general schematic view of an exemplary component as a representative workpiece; -
Figure 2 is an expanded cross section of the component; and -
Figure 3 is an expanded cross section of a repair to the component. -
Figure 1 schematically illustrates a general perspective view of anexemplary component 20, e.g., a fan blade with a multi-layer polyurethane erosion coating for a gas turbine engine. It should be appreciated that although a particular component type is illustrated in the disclosed non-limiting embodiment, other components with a multi-layer polyurethane coating will also benefit herefrom. - With reference to
Figure 2 , a cross-section of thecomponent 20 is illustrated for analuminum substrate 30 such as a 2000, 6000, or 7000 series aluminum with amulti-layer coating 35. Thecoating 35 includes a phosphoricacid anodizer layer 40, anepoxy bond primer 50 as a corrosion inhibitor, apaint primer 60, and anerosion coating 70 such as a urethane as the outer layer. It should be appreciated that various materials may be utilized in accords with this layer structure. - With reference to
Figure 3 , alocal repair 100 for thecomponent 20 may be performed on an airflow surface. That is, the local repair of damage may be performed in response to damage within the polyurethane coating stack up on thealuminum substrate 30. Thelocal repair 100 may be initiated by abrading down to thealuminum substrate 30 or for damage that has reached down to thealuminum substrate 30. The polyurethane coating stack adjacent to the damage may be abraded, feathered or otherwise prepared and cleaned with, for example aluminum oxide and an acetone wipe. - Next, a Sol-
Gel layer 110 is applied over thealuminum substrate 30 to react with thealuminum substrate 30 and thereby provide a stable surface. The Sol-Gellayer 110 may be provided with a 1hour room temperature cure. The Sol-Gel layer 110 process involves conversion of monomers into a colloidal solution (sol) that acts as the precursor for an integrated network (or gel) of either discrete particles or network polymers. The Sol-Gel layer 110 does not adversely react or effect adjacent coatings layers 40-70 such that masking is not otherwise required. - Next, the
paint primer 60 is applied over the Sol-Gel layer 110. The Sol-Gellayer 110 significantly improves the adhesion of paint primers within the coating stack up. Finally, theerosion coating 70 is applied over thepaint primer 60 to finalize thelocal repair 100. - The use of the terms "a," "an," "the," and similar references in the context of description (especially in the context of the following claims) are to be construed to cover both the singular and the plural, unless otherwise indicated herein or specifically contradicted by context. The modifier "about" used in connection with a quantity is inclusive of the stated value and has the meaning dictated by the context (e.g., it includes the degree of error associated with measurement of the particular quantity). All ranges disclosed herein are inclusive of the endpoints, and the endpoints are independently combinable with each other. It should be appreciated that relative positional terms such as "forward," "aft," "upper," "lower," "above," "below," and the like are with reference to the normal operational attitude of the vehicle and should not be considered otherwise limiting.
- Although the different non-limiting embodiments have specific illustrated components, the embodiments of this invention are not limited to those particular combinations. It is possible to use some of the components or features from any of the non-limiting embodiments in combination with features or components from any of the other non-limiting embodiments.
- It should be appreciated that like reference numerals identify corresponding or similar elements throughout the several drawings. It should also be appreciated that although a particular component arrangement is disclosed in the illustrated embodiment, other arrangements will benefit herefrom.
- Although particular step sequences are shown, described, and claimed, it should be appreciated that steps may be performed in any order, separated or combined unless otherwise indicated and will still benefit from the present disclosure.
- The foregoing description is exemplary rather than defined by the limitations within. Various non-limiting embodiments are disclosed herein, however, one of ordinary skill in the art would recognize that various modifications and variations in light of the above teachings will fall within the scope of the appended claims. It is therefore to be appreciated that within the scope of the appended claims, the disclosure may be practiced other than as specifically described. For that reason the appended claims should be studied to determine true scope and content.
Claims (10)
- A method, comprising:applying a Sol-Gel layer onto a substrate; andapplying an erosion coating layer over the Sol-Gel layer.
- The method as recited in claim 1, wherein the method is applied to a local area.
- The method as recited in claim 1 or claim 2, wherein the method provides for a local repair to a fan blade.
- The method as recited in any preceding claim, further comprising applying a paint primer to the Sol-Gel layer prior to applying the erosion coating layer.
- The method as recited in any preceding claim wherein the method provides for repair of a multi-layer polyurethane erosion coating.
- A component comprising:a local area with a Sol-Gel layer over an aluminum substrate.
- The component as recited in claim 6, further comprising an erosion coating is over the Sol-Gel layer.
- The component as recited in claim 7, further comprising a paint primer between the Sol-Gel layer and the erosion coating layer.
- The component as recited in any one of claims 6 to 8 wherein said component is a gas turbine engine component.
- The component as recited in any one of claims 6 to 8, wherein the component is a fan blade.
Applications Claiming Priority (1)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US201562387454P | 2015-12-24 | 2015-12-24 |
Publications (2)
Publication Number | Publication Date |
---|---|
EP3184735A2 true EP3184735A2 (en) | 2017-06-28 |
EP3184735A3 EP3184735A3 (en) | 2017-10-04 |
Family
ID=57681301
Family Applications (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
EP16204796.3A Withdrawn EP3184735A3 (en) | 2015-12-24 | 2016-12-16 | Local repair or remanufacture of polymeric erosion coatings |
Country Status (1)
Country | Link |
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EP (1) | EP3184735A3 (en) |
Cited By (3)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
EP3431712A1 (en) * | 2017-07-21 | 2019-01-23 | United Technologies Corporation | Method to strip and recoat erosion coatings applied to fan blades and structural guide vanes |
EP3434865A1 (en) * | 2017-07-21 | 2019-01-30 | United Technologies Corporation | Method to strip and recoat erosion coatings applied to fan blades and structural guide vanes |
US11346371B2 (en) * | 2018-05-04 | 2022-05-31 | Raytheon Technologies Corporation | Method to strip coatings off of an aluminum alloy fan blade |
Family Cites Families (3)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US5814137A (en) * | 1996-11-04 | 1998-09-29 | The Boeing Company | Sol for coating metals |
US6235352B1 (en) * | 1999-11-29 | 2001-05-22 | Electric Power Research Institute, Inc. | Method of repairing a thermal barrier coating |
US8221825B2 (en) * | 2009-03-30 | 2012-07-17 | Alstom Technology Ltd. | Comprehensive method for local application and local repair of thermal barrier coatings |
-
2016
- 2016-12-16 EP EP16204796.3A patent/EP3184735A3/en not_active Withdrawn
Non-Patent Citations (1)
Title |
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None |
Cited By (5)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
EP3431712A1 (en) * | 2017-07-21 | 2019-01-23 | United Technologies Corporation | Method to strip and recoat erosion coatings applied to fan blades and structural guide vanes |
EP3434865A1 (en) * | 2017-07-21 | 2019-01-30 | United Technologies Corporation | Method to strip and recoat erosion coatings applied to fan blades and structural guide vanes |
US11260421B2 (en) * | 2017-07-21 | 2022-03-01 | Raytheon Technologies Corporation | Method to strip and recoat erosion coatings applied to fan blades and structural guide vanes |
US11346371B2 (en) * | 2018-05-04 | 2022-05-31 | Raytheon Technologies Corporation | Method to strip coatings off of an aluminum alloy fan blade |
US11814983B2 (en) | 2018-05-04 | 2023-11-14 | Rtx Corporation | Method to strip coatings off of an aluminum alloy fan blade |
Also Published As
Publication number | Publication date |
---|---|
EP3184735A3 (en) | 2017-10-04 |
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