US20170016454A1 - Method for coating compressor blade tips - Google Patents
Method for coating compressor blade tips Download PDFInfo
- Publication number
- US20170016454A1 US20170016454A1 US14/630,965 US201514630965A US2017016454A1 US 20170016454 A1 US20170016454 A1 US 20170016454A1 US 201514630965 A US201514630965 A US 201514630965A US 2017016454 A1 US2017016454 A1 US 2017016454A1
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- US
- United States
- Prior art keywords
- coating
- abrasive
- component
- blade
- blade tip
- 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.)
- Abandoned
Links
- 238000000034 method Methods 0.000 title claims abstract description 67
- 239000011248 coating agent Substances 0.000 title claims abstract description 57
- 238000000576 coating method Methods 0.000 title claims abstract description 57
- 239000003082 abrasive agent Substances 0.000 claims abstract description 39
- 238000000151 deposition Methods 0.000 claims abstract description 25
- 230000008021 deposition Effects 0.000 claims abstract description 16
- 238000010892 electric spark Methods 0.000 claims abstract description 16
- VYPSYNLAJGMNEJ-UHFFFAOYSA-N Silicium dioxide Chemical compound O=[Si]=O VYPSYNLAJGMNEJ-UHFFFAOYSA-N 0.000 claims description 14
- GWEVSGVZZGPLCZ-UHFFFAOYSA-N Titan oxide Chemical compound O=[Ti]=O GWEVSGVZZGPLCZ-UHFFFAOYSA-N 0.000 claims description 14
- MCMNRKCIXSYSNV-UHFFFAOYSA-N Zirconium dioxide Chemical compound O=[Zr]=O MCMNRKCIXSYSNV-UHFFFAOYSA-N 0.000 claims description 14
- 241000588731 Hafnia Species 0.000 claims description 7
- 229910052782 aluminium Inorganic materials 0.000 claims description 7
- XAGFODPZIPBFFR-UHFFFAOYSA-N aluminium Chemical compound [Al] XAGFODPZIPBFFR-UHFFFAOYSA-N 0.000 claims description 7
- PNEYBMLMFCGWSK-UHFFFAOYSA-N aluminium oxide Inorganic materials [O-2].[O-2].[O-2].[Al+3].[Al+3] PNEYBMLMFCGWSK-UHFFFAOYSA-N 0.000 claims description 7
- CETPSERCERDGAM-UHFFFAOYSA-N ceric oxide Chemical compound O=[Ce]=O CETPSERCERDGAM-UHFFFAOYSA-N 0.000 claims description 7
- 229910000422 cerium(IV) oxide Inorganic materials 0.000 claims description 7
- QDOXWKRWXJOMAK-UHFFFAOYSA-N dichromium trioxide Chemical compound O=[Cr]O[Cr]=O QDOXWKRWXJOMAK-UHFFFAOYSA-N 0.000 claims description 7
- CJNBYAVZURUTKZ-UHFFFAOYSA-N hafnium(IV) oxide Inorganic materials O=[Hf]=O CJNBYAVZURUTKZ-UHFFFAOYSA-N 0.000 claims description 7
- 229910044991 metal oxide Inorganic materials 0.000 claims description 7
- 150000004706 metal oxides Chemical class 0.000 claims description 7
- 239000000377 silicon dioxide Substances 0.000 claims description 7
- 230000003746 surface roughness Effects 0.000 claims description 7
- 230000000873 masking effect Effects 0.000 claims description 6
- 239000000956 alloy Substances 0.000 claims description 5
- 229910045601 alloy Inorganic materials 0.000 claims description 5
- 239000011651 chromium Substances 0.000 claims description 5
- VYZAMTAEIAYCRO-UHFFFAOYSA-N Chromium Chemical compound [Cr] VYZAMTAEIAYCRO-UHFFFAOYSA-N 0.000 claims description 4
- 229910052804 chromium Inorganic materials 0.000 claims description 4
- 229910052582 BN Inorganic materials 0.000 claims description 3
- PZNSFCLAULLKQX-UHFFFAOYSA-N Boron nitride Chemical compound N#B PZNSFCLAULLKQX-UHFFFAOYSA-N 0.000 claims description 3
- 229910052684 Cerium Inorganic materials 0.000 claims description 3
- XUIMIQQOPSSXEZ-UHFFFAOYSA-N Silicon Chemical compound [Si] XUIMIQQOPSSXEZ-UHFFFAOYSA-N 0.000 claims description 3
- RTAQQCXQSZGOHL-UHFFFAOYSA-N Titanium Chemical compound [Ti] RTAQQCXQSZGOHL-UHFFFAOYSA-N 0.000 claims description 3
- QCWXUUIWCKQGHC-UHFFFAOYSA-N Zirconium Chemical compound [Zr] QCWXUUIWCKQGHC-UHFFFAOYSA-N 0.000 claims description 3
- INAHAJYZKVIDIZ-UHFFFAOYSA-N boron carbide Chemical compound B12B3B4C32B41 INAHAJYZKVIDIZ-UHFFFAOYSA-N 0.000 claims description 3
- GWXLDORMOJMVQZ-UHFFFAOYSA-N cerium Chemical compound [Ce] GWXLDORMOJMVQZ-UHFFFAOYSA-N 0.000 claims description 3
- 229910003460 diamond Inorganic materials 0.000 claims description 3
- 239000010432 diamond Substances 0.000 claims description 3
- 229910052735 hafnium Inorganic materials 0.000 claims description 3
- VBJZVLUMGGDVMO-UHFFFAOYSA-N hafnium atom Chemical compound [Hf] VBJZVLUMGGDVMO-UHFFFAOYSA-N 0.000 claims description 3
- 229910052710 silicon Inorganic materials 0.000 claims description 3
- 239000010703 silicon Substances 0.000 claims description 3
- 229910010271 silicon carbide Inorganic materials 0.000 claims description 3
- HBMJWWWQQXIZIP-UHFFFAOYSA-N silicon carbide Chemical compound [Si+]#[C-] HBMJWWWQQXIZIP-UHFFFAOYSA-N 0.000 claims description 3
- 239000010936 titanium Substances 0.000 claims description 3
- 229910052719 titanium Inorganic materials 0.000 claims description 3
- MTPVUVINMAGMJL-UHFFFAOYSA-N trimethyl(1,1,2,2,2-pentafluoroethyl)silane Chemical compound C[Si](C)(C)C(F)(F)C(F)(F)F MTPVUVINMAGMJL-UHFFFAOYSA-N 0.000 claims description 3
- UONOETXJSWQNOL-UHFFFAOYSA-N tungsten carbide Chemical compound [W+]#[C-] UONOETXJSWQNOL-UHFFFAOYSA-N 0.000 claims description 3
- 229910052726 zirconium Inorganic materials 0.000 claims description 3
- 229910052580 B4C Inorganic materials 0.000 claims description 2
- 239000000463 material Substances 0.000 description 24
- 239000007789 gas Substances 0.000 description 17
- 238000005524 ceramic coating Methods 0.000 description 7
- 229910052751 metal Inorganic materials 0.000 description 5
- 239000002184 metal Substances 0.000 description 5
- 230000008569 process Effects 0.000 description 4
- 238000011144 upstream manufacturing Methods 0.000 description 4
- 239000000919 ceramic Substances 0.000 description 3
- 239000000567 combustion gas Substances 0.000 description 3
- 239000007772 electrode material Substances 0.000 description 3
- PXHVJJICTQNCMI-UHFFFAOYSA-N nickel Substances [Ni] PXHVJJICTQNCMI-UHFFFAOYSA-N 0.000 description 3
- 239000002245 particle Substances 0.000 description 3
- 230000008901 benefit Effects 0.000 description 2
- 238000000752 ionisation method Methods 0.000 description 2
- 238000007747 plating Methods 0.000 description 2
- 239000007921 spray Substances 0.000 description 2
- 238000005275 alloying Methods 0.000 description 1
- 238000013459 approach Methods 0.000 description 1
- 239000010953 base metal Substances 0.000 description 1
- 239000003990 capacitor Substances 0.000 description 1
- 239000010941 cobalt Substances 0.000 description 1
- 229910017052 cobalt Inorganic materials 0.000 description 1
- GUTLYIVDDKVIGB-UHFFFAOYSA-N cobalt atom Chemical compound [Co] GUTLYIVDDKVIGB-UHFFFAOYSA-N 0.000 description 1
- 238000002485 combustion reaction Methods 0.000 description 1
- 230000008878 coupling Effects 0.000 description 1
- 238000010168 coupling process Methods 0.000 description 1
- 238000005859 coupling reaction Methods 0.000 description 1
- 230000003247 decreasing effect Effects 0.000 description 1
- 238000005137 deposition process Methods 0.000 description 1
- 239000012530 fluid Substances 0.000 description 1
- 239000000446 fuel Substances 0.000 description 1
- 230000004927 fusion Effects 0.000 description 1
- 238000004519 manufacturing process Methods 0.000 description 1
- 238000001465 metallisation Methods 0.000 description 1
- 150000002739 metals Chemical class 0.000 description 1
- 239000000203 mixture Substances 0.000 description 1
- 238000012986 modification Methods 0.000 description 1
- 230000004048 modification Effects 0.000 description 1
- 229910052759 nickel Inorganic materials 0.000 description 1
- 230000003647 oxidation Effects 0.000 description 1
- 238000007254 oxidation reaction Methods 0.000 description 1
- TWNQGVIAIRXVLR-UHFFFAOYSA-N oxo(oxoalumanyloxy)alumane Chemical compound O=[Al]O[Al]=O TWNQGVIAIRXVLR-UHFFFAOYSA-N 0.000 description 1
- 230000009467 reduction Effects 0.000 description 1
- 230000007704 transition Effects 0.000 description 1
- 229910052727 yttrium Inorganic materials 0.000 description 1
- VWQVUPCCIRVNHF-UHFFFAOYSA-N yttrium atom Chemical group [Y] VWQVUPCCIRVNHF-UHFFFAOYSA-N 0.000 description 1
Images
Classifications
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
- B23K9/00—Arc welding or cutting
- B23K9/04—Welding for other purposes than joining, e.g. built-up welding
- B23K9/044—Built-up welding on three-dimensional surfaces
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F04—POSITIVE - DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS FOR LIQUIDS OR ELASTIC FLUIDS
- F04D—NON-POSITIVE-DISPLACEMENT PUMPS
- F04D29/00—Details, component parts, or accessories
- F04D29/26—Rotors specially for elastic fluids
- F04D29/32—Rotors specially for elastic fluids for axial flow pumps
- F04D29/321—Rotors specially for elastic fluids for axial flow pumps for axial flow compressors
- F04D29/324—Blades
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
- B23K9/00—Arc welding or cutting
- B23K9/23—Arc welding or cutting taking account of the properties of the materials to be welded
-
- 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
- C23C26/00—Coating not provided for in groups C23C2/00 - C23C24/00
-
- 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
- F04—POSITIVE - DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS FOR LIQUIDS OR ELASTIC FLUIDS
- F04D—NON-POSITIVE-DISPLACEMENT PUMPS
- F04D29/00—Details, component parts, or accessories
- F04D29/02—Selection of particular materials
- F04D29/023—Selection of particular materials especially adapted for elastic fluid pumps
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F04—POSITIVE - DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS FOR LIQUIDS OR ELASTIC FLUIDS
- F04D—NON-POSITIVE-DISPLACEMENT PUMPS
- F04D29/00—Details, component parts, or accessories
- F04D29/40—Casings; Connections of working fluid
- F04D29/52—Casings; Connections of working fluid for axial pumps
- F04D29/522—Casings; Connections of working fluid for axial pumps especially adapted for elastic fluid pumps
- F04D29/526—Details of the casing section radially opposing blade tips
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
- B23K2101/00—Articles made by soldering, welding or cutting
- B23K2101/001—Turbines
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
- B23K2103/00—Materials to be soldered, welded or cut
- B23K2103/18—Dissimilar materials
- B23K2103/26—Alloys of Nickel and Cobalt and Chromium
-
- 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
- F05D2230/00—Manufacture
- F05D2230/30—Manufacture with deposition of material
-
- 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
- F05D2230/00—Manufacture
- F05D2230/90—Coating; Surface treatment
-
- 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
- F05D2300/20—Oxide or non-oxide ceramics
- F05D2300/22—Non-oxide ceramics
- F05D2300/226—Carbides
Definitions
- Gas turbine engines include one or more compressors for compressing air prior to combustion.
- One or more rows of compressor blades extend radially outward from a hub or rotor and towards an inner surface of the compressor casing.
- the blades rotate about a central axis and direct the flow of and compress fluids (e.g., air) within the compressor.
- a seal is formed between the radially outermost end of a compressor blade, the blade tip, and the inner surface of the casing.
- the blade tip is coated with an abrasive material and the inner surface of the casing is coated with an abradable material to form a seal.
- the abrasive material on the blade tip rubs against and abrades the abradable material on the casing to form a tight seal between the blade tip and the casing. Maintaining a tight air seal between the blades and compressor casing is needed for optimum gas turbine engine operation.
- a method for forming a component having an abrasive portion includes forming the component and selectively forming a coating on the component using electric spark deposition to form the abrasive portion.
- a method for coating a blade tip with an abrasive material includes forming a blade having a tip and depositing a coating on the blade tip using electric spark deposition.
- a method includes providing a casing having an inner diameter surface, locating an abradable coating on a portion of the inner diameter surface, providing a blade configured to rotate within the casing and having a blade tip where the blade tip and the inner diameter surface of the casing form a seal, and depositing an abrasive coating on the blade tip using electric spark deposition so that the abrasive coating and abradable coating interact during rotation of the blade within the casing.
- FIG. 1 is a cross section view of a gas turbine engine.
- FIG. 2 is a cross section view of a compressor illustrating a blade and compressor casing.
- FIG. 3 is a view of a compressor blade tip and an electric spark discharge electrode.
- the present disclosure describes a method for applying a ceramic coating on compressor blade tips.
- Electric spark discharge (ESD) is used to apply the ceramic coating to blade tips.
- ESD allows the thin blade tips to be coated without the need for masking other portions of the blade, reducing manufacturing time and costs.
- the resulting ceramic coating has low thermal conductivity compared to the base metal of the blade, has strength at elevated surface temperatures to produce a desired wear ratio, and has surface roughness to aid in reducing rub forces and surface temperature.
- FIG. 1 illustrates a cross-sectional view of gas turbine engine 20 .
- Gas turbine engine 20 includes fan 22 with bypass duct 24 oriented about a turbine core having compressor section 26 , combustor section 28 , and turbine section 30 , which are arranged in flow series along an axial direction with an upstream inlet 32 and downstream exhaust 34 .
- Turbine section 30 includes high-pressure turbine (HPT) section 36 and low-pressure turbine (LPT) section 38 .
- Turbine sections 36 and 38 each have a number of alternating turbine blades 40 and turbine vanes 42 .
- Turbine vanes 42 are circumferentially oriented with respect to one another, and collectively form a full, annular vane ring about turbine centerline axis C L of gas turbine engine 20 .
- HPT section 36 of turbine 30 is coupled to compressor section 26 via shaft 44 , forming the high pressure spool.
- LPT section 38 is coupled to fan 22 via shaft 46 , forming the low pressure spool.
- Shaft 46 is coaxially mounted within shaft 44 , about turbine centerline axis C L .
- Fan 22 is typically mounted to a fan disk or other rotating member, which is driven by shaft 46 .
- fan 22 is forward-mounted in engine cowling 48 , upstream of bypass duct 24 and compressor section 26 , with spinner 50 covering the fan disk to improve aerodynamic performance.
- fan 22 is aft-mounted in a downstream location, and the coupling configuration varies.
- FIG. 1 illustrates a particular two-spool high-bypass turbofan embodiment of gas turbine engine 20 , this example is merely illustrative. In other embodiments, gas turbine engine 20 is configured either as a low-bypass turbofan or a high-bypass turbofan, as described above, and the number of spools and fan position vary.
- airflow F enters via upstream inlet 32 and divides into bypass flow F B and core flow F C downstream of fan 22 .
- Bypass flow F B passes through bypass duct 24 and generates thrust;
- core flow F C passes along the gas path through compressor section 26 , combustor section 28 and turbine section 30 .
- Compressor section 26 includes low pressure compressor 52 and high pressure compressor 54 , which together compress incoming air for combustor section 28 where it is mixed with fuel and ignited to produce hot combustion gas.
- the combustion gas exits combustor section 28 and enters HPT section 36 of turbine section 30 , driving shaft 44 and thereby compressor section 26 .
- Partially expanded combustion gas transitions from HPT section 36 to LPT section 38 , driving fan 22 via shaft 46 .
- Exhaust gas exits gas turbine engine 20 via downstream exhaust 34 .
- thermodynamic efficiency of gas turbine engine 20 is strongly tied to the overall pressure ratio, as defined between the compressed air pressure entering combustor section 28 and the delivery pressure at upstream inlet 32 .
- higher pressure ratios offer increased greater specific thrust, and may result in higher peak gas path temperatures, particularly downstream of combustor section 28 , including HPT section 36 .
- FIG. 2 illustrates a cross section view of a compressor showing blade 60 and compressor casing 62 .
- Blade 60 rotates within compressor casing 62 to compress air from fan 22 before it is delivered to combustor section 28 .
- blade 60 is part of an integrally bladed rotor.
- Blade tip 64 is located at a radially outward portion of blade 60 .
- Abradable material 66 is located at a radially inward portion of casing 62 .
- blade 60 and casing 62 must form a tight seal.
- One way to seal blade 60 and casing 62 is to form or coat blade tip 64 with an abrasive (abrasive material 68 ) and position abradable material 66 along inner surface 68 of casing 62 directly across from blade tip 64 .
- abrasive abrasive material 68
- abradable material 66 rub against one another.
- a portion of abradable material 66 is worn away. Just enough abradable material 66 is removed so that a tight seal is formed between blade tip 64 and casing 22 .
- Abradable material 66 can be “soft” and have a porosity that makes it abradable with respect to bare metal blades. Alternatively, abradable material 66 can be generally “hard” and have a higher density and smoother surface be and gas impermeable. “Hard” abradables typically yield improved efficiency when compared to “soft” abradables. In some embodiments, abradable material 66 is a CoNiCrAlY or NiCoCrAlY alloy, where Co is cobalt, Ni is nickel, Cr is chromium, Al is aluminum and Y is yttrium. Blade tip 64 is constructed from abrasive material 68 or abrasive material 68 is applied to blade tip 64 .
- blade 60 is a metallic blade and abrasive material 68 applied to blade tip 64 is a ceramic coating.
- Abrasive material 68 is generally stronger than abradable material 66 so that blade tip 64 cuts into abradable material 66 to form the seal.
- wear occurs on both abradable material 66 and abrasive material 68 .
- blade tip 64 can soften at high temperatures and experience increased wear.
- ESD is used to coat blade tip 64 with abrasive material 68 .
- ESD is a contact metal deposition process.
- ESD is also sometimes referred to as electrospark deposition, spark hardening, electrospark toughening, electrospark alloying, pulse fusion surfacing and pulse electrode surfacing.
- FIG. 3 illustrates a system and method for applying abrasive material 68 to blade tip 64 by ESD.
- ESD device 72 includes capacitor-based power supply 74 and electrode 76 .
- Abrasive material 68 is formed on blade tip 64 by electrode 76 .
- Electrode 76 is positioned so that it is very close to or contacting blade tip 64 .
- power supply 74 a voltage is applied to electrode 76 .
- a voltage is also applied to blade 60 .
- the voltage applied to electrode 76 is greater than that applied to blade 60 , and blade 60 acts as a ground.
- the voltage difference between electrode 76 and blade 60 generates a plasma arc at a high temperature between electrode 76 and blade tip 64 . In some embodiments the temperature ranges from about 8,000° C.
- Electrode 76 is positioned at another location along blade tip 64 and the arc/ionization process is repeated until abrasive material 68 is applied to the desired part of blade tip 64 .
- electrode 76 contains a material selected from the group consisting of aluminum, zirconium, chromium, hafnium, cerium, titanium, silicon and combinations thereof. Some amount of oxidation generally occurs as a result of the arc/ionization process.
- the metal(s) of electrode 76 are deposited on blade tip 64 as metal(s) and metal oxides. Therefore, the deposited abrasive material 68 can be a ceramic coating.
- abrasive material 68 is a ceramic selected from the group consisting of alumina, zirconia, chromia, hafnia, ceria, titania, silica and combinations thereof.
- abrasive material 68 is between about 25% metal oxide by volume and about 100% metal oxide by volume. In particular embodiments, abrasive material 68 is greater than about 75% metal oxide by volume. Having some metal content (in addition to the metal oxide content) within abrasive material 68 can provide a strength or spallation benefit to blade tip 64 .
- Electrode 76 can also contain fine ceramic particles along with metals such as those listed above. Electrode 76 can include aluminum oxide particles having average diameters between about 1 and 10 microns. Including ceramic particles in and on electrode 76 can increase the speed that abrasive material 68 is formed on blade tip 64 as less material must be oxidized.
- Non-oxide materials can also be deposited on blade tip 64 as abrasive material 68 .
- electrode 76 contains materials including, but not limited to, silicon carbide, tungsten carbide, titanium carbide, boron carbide (B 4 C), cubic boron nitride, aluminum diboride, diamond and combinations thereof.
- the deposition process described above occurs in a process bath where electrode 76 approaches blade tip 64 with a small clearance therebetween. Blade tip 64 and/or electrode 76 are rotated during deposition. Rotation of electrode 76 and blade tip 64 can help to evenly distribute molten electrode material to blade tip 64 .
- the disclosed ESD method does not require masking parts of blade 60 . ESD allows selective placement of abrasive material 68 to blade tips 64 .
- Abrasive material 68 can be deposited onto blade tip 64 at varying thicknesses.
- abrasive material 68 is applied to blade tip 64 so that it has a thickness between about 0.025 millimeters (0.001 inches) and about 0.51 millimeters (0.020 inches).
- abrasive material 68 is applied to blade tip 64 so that it has a thickness between about 0.10 millimeters (0.004 inches) and about 0.305 millimeters (0.012 inches).
- the disclosed ESD method can provide blade tip 64 with abrasive material 68 having a roughened surface.
- a roughened surface reduces the number of contact points between blade tip 64 and abradable material 66 , thereby reducing the surface temperatures while blade tip 64 rubs abradable material 66 .
- the reduction in temperature reduces the amount of wear on abrasive material 68 and blade tip 64 .
- abrasive material 68 applied to blade tip 64 has a surface roughness (R a ) between about 1.25 micrometers (50 microinches) and about 5 micrometers (200 microinches).
- the surface roughness of abrasive material 68 and blade tip 64 can be adjusted by varying the ESD parameters to create a desired wear ratio between abrasive material 68 and abradable material 66 .
- the surface roughness provided to abrasive material 68 creates a volumetric wear ratio of abrasive material 68 to abradable material 64 between about 1:50 and about 1:500.
- the surface roughness provided to abrasive material 68 creates a wear ratio of abrasive material 68 to abradable material 66 of about 1:400.
- Forming a ceramic coating on blade tip 64 according to the disclosed ESD method provides advantages over other deposition techniques. ESD does not require the use of masks needed for thermal spray and plating processes. ESD can also create a roughened ceramic coating on blade tips to reduce blade wear and/or generate a desired wear pattern. While the disclosed ESD method has been described with reference to a compressor blade tip for a gas turbine engine, other components, such as those in industrial gas turbine applications, having an abrasive material can be formed in a similar manner.
- a method for forming a component having an abrasive portion can include forming the component and selectively forming a coating on the component using electric spark deposition to form the abrasive portion.
- the method of the preceding paragraph can optionally include, additionally and/or alternatively, any one or more of the following features, configurations and/or additional components:
- a further embodiment of the foregoing method can include that the component is a blade and that the abrasive portion is located at a blade tip.
- a further embodiment of any of the foregoing methods can include that the coating has a surface roughness (R a ) between about 1.25 micrometers (50 microinches) and about 5 micrometers (200 microinches).
- a further embodiment of any of the foregoing methods can include that the coating has a thickness between about 0.025 millimeters (0.001 inches) and about 0.51 millimeters (0.020 inches).
- a further embodiment of any of the foregoing methods can include that the coating has a thickness between about 0.10 millimeters (0.004 inches) and about 0.305 millimeters (0.012 inches).
- a further embodiment of any of the foregoing methods can include that the coating is selected from the group consisting of alumina, zirconia, chromia, hafnia, ceria, titania, silica and combinations thereof.
- a further embodiment of any of the foregoing methods can include that the coating is selected from the group consisting of silicon carbide, tungsten carbide, titanium carbide, boron carbide, cubic boron nitride, aluminum diboride, diamond and combinations thereof.
- a further embodiment of any of the foregoing methods can include that a metal oxide content of the coating is between about 25% by weight and about 100% by weight.
- a further embodiment of any of the foregoing methods can include that the step of selectively forming the coating on the component using electric spark deposition includes applying a voltage between an electrode containing aluminum, zirconium, chromium, hafnium, cerium, titanium, silicon and combinations thereof and the component and moving the electrode toward the component so that a portion of the electrode is deposited on the component.
- a further embodiment of any of the foregoing methods can include that the coating is formed to provide an abrasive:abradable wear ratio of the abrasive portion of the component to an abradable portion of a stationary component adjacent the component, and wherein the abrasive:abradable wear ratio is between about 1:50 and about 1:500.
- a further embodiment of any of the foregoing methods can include that the abrasive:abradable wear ratio is about 1:400.
- a further embodiment of any of the foregoing methods can include that the abradable portion of a stationary component comprises a CoNiCrAlY or NiCoCrAlY alloy.
- a further embodiment of any of the foregoing methods can include that the coating is formed without use of masking techniques.
- a method for coating a blade tip with an abrasive material can include forming a blade having a tip and depositing a coating on the blade tip using electric spark deposition.
- the method of the preceding paragraph can optionally include, additionally and/or alternatively, any one or more of the following features, configurations and/or additional components:
- a further embodiment of the foregoing method can include that the coating is formed without use of masking techniques.
- a further embodiment of any of the foregoing methods can include that coating comprises alumina, zirconia, chromia, hafnia, ceria, titania, silica and combinations thereof.
- a method can include providing a casing having an inner diameter surface, locating an abradable coating on a portion of the inner diameter surface, providing a blade configured to rotate within the casing and having a blade tip where the blade tip and the inner diameter surface of the casing form a seal, and depositing an abrasive coating on the blade tip using electric spark deposition so that the abrasive coating and abradable coating interact during rotation of the blade within the casing.
- the method of the preceding paragraph can optionally include, additionally and/or alternatively, any one or more of the following features, configurations and/or additional components:
- a further embodiment of the foregoing method can include that the abradable coating comprises a CoNiCrAlY or NiCoCrAlY alloy.
- a further embodiment of any of the foregoing methods can include that the abrasive coating has a thickness between about 0.025 millimeters (0.001 inches) and about 0.51 millimeters (0.020 inches).
- a further embodiment of any of the foregoing methods can include that the abrasive coating comprises alumina, zirconia, chromia, hafnia, ceria, titania, silica and combinations thereof.
Abstract
A method for forming a component having an abrasive portion includes forming the component and selectively forming a coating on the component using electric spark deposition to form the abrasive portion. A method for coating a blade tip with an abrasive material includes forming a blade having a tip and depositing a coating on the blade tip using electric spark deposition. A method includes providing a casing having an inner diameter surface, locating an abradable coating on a portion of the inner diameter surface, providing a blade configured to rotate within the casing and having a blade tip where the blade tip and the inner diameter surface of the casing form a seal, and depositing an abrasive coating on the blade tip using electric spark deposition so that the abrasive coating and abradable coating interact during rotation of the blade within the casing.
Description
- Gas turbine engines include one or more compressors for compressing air prior to combustion. One or more rows of compressor blades extend radially outward from a hub or rotor and towards an inner surface of the compressor casing. During operation, the blades rotate about a central axis and direct the flow of and compress fluids (e.g., air) within the compressor. A seal is formed between the radially outermost end of a compressor blade, the blade tip, and the inner surface of the casing. In some compressors, the blade tip is coated with an abrasive material and the inner surface of the casing is coated with an abradable material to form a seal. During rotation, the abrasive material on the blade tip rubs against and abrades the abradable material on the casing to form a tight seal between the blade tip and the casing. Maintaining a tight air seal between the blades and compressor casing is needed for optimum gas turbine engine operation.
- A method for forming a component having an abrasive portion includes forming the component and selectively forming a coating on the component using electric spark deposition to form the abrasive portion.
- A method for coating a blade tip with an abrasive material includes forming a blade having a tip and depositing a coating on the blade tip using electric spark deposition.
- A method includes providing a casing having an inner diameter surface, locating an abradable coating on a portion of the inner diameter surface, providing a blade configured to rotate within the casing and having a blade tip where the blade tip and the inner diameter surface of the casing form a seal, and depositing an abrasive coating on the blade tip using electric spark deposition so that the abrasive coating and abradable coating interact during rotation of the blade within the casing.
-
FIG. 1 is a cross section view of a gas turbine engine. -
FIG. 2 is a cross section view of a compressor illustrating a blade and compressor casing. -
FIG. 3 is a view of a compressor blade tip and an electric spark discharge electrode. - The present disclosure describes a method for applying a ceramic coating on compressor blade tips. Electric spark discharge (ESD) is used to apply the ceramic coating to blade tips. ESD allows the thin blade tips to be coated without the need for masking other portions of the blade, reducing manufacturing time and costs. The resulting ceramic coating has low thermal conductivity compared to the base metal of the blade, has strength at elevated surface temperatures to produce a desired wear ratio, and has surface roughness to aid in reducing rub forces and surface temperature.
-
FIG. 1 illustrates a cross-sectional view ofgas turbine engine 20.Gas turbine engine 20 includesfan 22 withbypass duct 24 oriented about a turbine core havingcompressor section 26,combustor section 28, andturbine section 30, which are arranged in flow series along an axial direction with anupstream inlet 32 anddownstream exhaust 34. -
Turbine section 30 includes high-pressure turbine (HPT)section 36 and low-pressure turbine (LPT)section 38.Turbine sections alternating turbine blades 40 andturbine vanes 42.Turbine vanes 42 are circumferentially oriented with respect to one another, and collectively form a full, annular vane ring about turbine centerline axis CL ofgas turbine engine 20.HPT section 36 ofturbine 30 is coupled tocompressor section 26 viashaft 44, forming the high pressure spool.LPT section 38 is coupled tofan 22 viashaft 46, forming the low pressure spool.Shaft 46 is coaxially mounted withinshaft 44, about turbine centerline axis CL. -
Fan 22 is typically mounted to a fan disk or other rotating member, which is driven byshaft 46. As shown inFIG. 1 , for example,fan 22 is forward-mounted in engine cowling 48, upstream ofbypass duct 24 andcompressor section 26, withspinner 50 covering the fan disk to improve aerodynamic performance. Alternatively,fan 22 is aft-mounted in a downstream location, and the coupling configuration varies. Furthermore, whileFIG. 1 illustrates a particular two-spool high-bypass turbofan embodiment ofgas turbine engine 20, this example is merely illustrative. In other embodiments,gas turbine engine 20 is configured either as a low-bypass turbofan or a high-bypass turbofan, as described above, and the number of spools and fan position vary. - In operation of
gas turbine engine 20, airflow F enters viaupstream inlet 32 and divides into bypass flow FB and core flow FC downstream offan 22. Bypass flow FB passes throughbypass duct 24 and generates thrust; core flow FC passes along the gas path throughcompressor section 26,combustor section 28 andturbine section 30. -
Compressor section 26 includeslow pressure compressor 52 andhigh pressure compressor 54, which together compress incoming air forcombustor section 28 where it is mixed with fuel and ignited to produce hot combustion gas. The combustion gasexits combustor section 28 and enters HPTsection 36 ofturbine section 30, drivingshaft 44 and therebycompressor section 26. Partially expanded combustion gas transitions from HPTsection 36 toLPT section 38, drivingfan 22 viashaft 46. Exhaust gas exitsgas turbine engine 20 viadownstream exhaust 34. - The thermodynamic efficiency of
gas turbine engine 20 is strongly tied to the overall pressure ratio, as defined between the compressed air pressure enteringcombustor section 28 and the delivery pressure atupstream inlet 32. In general, higher pressure ratios offer increased greater specific thrust, and may result in higher peak gas path temperatures, particularly downstream ofcombustor section 28, includingHPT section 36. -
FIG. 2 illustrates a cross section view of a compressor showingblade 60 andcompressor casing 62.Blade 60 rotates withincompressor casing 62 to compress air fromfan 22 before it is delivered tocombustor section 28. In some embodiments,blade 60 is part of an integrally bladed rotor.Blade tip 64 is located at a radially outward portion ofblade 60.Abradable material 66 is located at a radially inward portion ofcasing 62. In order to operate at peak efficiency,blade 60 andcasing 62 must form a tight seal. One way to sealblade 60 andcasing 62 is to form orcoat blade tip 64 with an abrasive (abrasive material 68) and positionabradable material 66 alonginner surface 68 ofcasing 62 directly across fromblade tip 64. Asblade 60 rotates, temperatures within the compressor increase,blade 60 andcasing 62 expand, and blade tip 64 (with abrasive material 68) andabradable material 66 rub against one another. As the two components rub, a portion ofabradable material 66 is worn away. Just enoughabradable material 66 is removed so that a tight seal is formed betweenblade tip 64 andcasing 22. -
Abradable material 66 can be “soft” and have a porosity that makes it abradable with respect to bare metal blades. Alternatively,abradable material 66 can be generally “hard” and have a higher density and smoother surface be and gas impermeable. “Hard” abradables typically yield improved efficiency when compared to “soft” abradables. In some embodiments,abradable material 66 is a CoNiCrAlY or NiCoCrAlY alloy, where Co is cobalt, Ni is nickel, Cr is chromium, Al is aluminum and Y is yttrium.Blade tip 64 is constructed fromabrasive material 68 orabrasive material 68 is applied toblade tip 64. In some embodiments,blade 60 is a metallic blade andabrasive material 68 applied toblade tip 64 is a ceramic coating.Abrasive material 68 is generally stronger thanabradable material 66 so thatblade tip 64 cuts intoabradable material 66 to form the seal. However, wear occurs on bothabradable material 66 andabrasive material 68. Depending on composition,blade tip 64 can soften at high temperatures and experience increased wear. - The present disclosure describes a blade tip, and a method for forming such a blade tip, that experiences decreased wear even when paired with “hard” abradable materials. As described herein, ESD is used to coat
blade tip 64 withabrasive material 68. ESD is a contact metal deposition process. ESD is also sometimes referred to as electrospark deposition, spark hardening, electrospark toughening, electrospark alloying, pulse fusion surfacing and pulse electrode surfacing. -
FIG. 3 illustrates a system and method for applyingabrasive material 68 toblade tip 64 by ESD.ESD device 72 includes capacitor-based power supply 74 andelectrode 76.Abrasive material 68 is formed onblade tip 64 byelectrode 76.Electrode 76 is positioned so that it is very close to or contactingblade tip 64. Using power supply 74, a voltage is applied toelectrode 76. A voltage is also applied toblade 60. The voltage applied toelectrode 76 is greater than that applied toblade 60, andblade 60 acts as a ground. The voltage difference betweenelectrode 76 andblade 60 generates a plasma arc at a high temperature betweenelectrode 76 andblade tip 64. In some embodiments the temperature ranges from about 8,000° C. to about 25,000° C. The plasma arc ionizes a portion ofelectrode 76 and a small amount of molten electrode material is transferred fromelectrode 76 toblade tip 64. The molten electrode material solidifies onblade tip 64 asabrasive material 68.Electrode 76 is positioned at another location alongblade tip 64 and the arc/ionization process is repeated untilabrasive material 68 is applied to the desired part ofblade tip 64. - In some embodiments,
electrode 76 contains a material selected from the group consisting of aluminum, zirconium, chromium, hafnium, cerium, titanium, silicon and combinations thereof. Some amount of oxidation generally occurs as a result of the arc/ionization process. Thus, the metal(s) ofelectrode 76 are deposited onblade tip 64 as metal(s) and metal oxides. Therefore, the depositedabrasive material 68 can be a ceramic coating. In some embodiments,abrasive material 68 is a ceramic selected from the group consisting of alumina, zirconia, chromia, hafnia, ceria, titania, silica and combinations thereof. In some embodiments,abrasive material 68 is between about 25% metal oxide by volume and about 100% metal oxide by volume. In particular embodiments,abrasive material 68 is greater than about 75% metal oxide by volume. Having some metal content (in addition to the metal oxide content) withinabrasive material 68 can provide a strength or spallation benefit toblade tip 64. -
Electrode 76 can also contain fine ceramic particles along with metals such as those listed above.Electrode 76 can include aluminum oxide particles having average diameters between about 1 and 10 microns. Including ceramic particles in and onelectrode 76 can increase the speed thatabrasive material 68 is formed onblade tip 64 as less material must be oxidized. - Non-oxide materials can also be deposited on
blade tip 64 asabrasive material 68. In these embodiments,electrode 76 contains materials including, but not limited to, silicon carbide, tungsten carbide, titanium carbide, boron carbide (B4C), cubic boron nitride, aluminum diboride, diamond and combinations thereof. - In some embodiments, the deposition process described above occurs in a process bath where
electrode 76 approachesblade tip 64 with a small clearance therebetween.Blade tip 64 and/orelectrode 76 are rotated during deposition. Rotation ofelectrode 76 andblade tip 64 can help to evenly distribute molten electrode material toblade tip 64. Unlike other processes for making abrasive blade tips, such as thermal spray or plating, the disclosed ESD method does not require masking parts ofblade 60. ESD allows selective placement ofabrasive material 68 toblade tips 64. -
Abrasive material 68 can be deposited ontoblade tip 64 at varying thicknesses. In some embodiments,abrasive material 68 is applied toblade tip 64 so that it has a thickness between about 0.025 millimeters (0.001 inches) and about 0.51 millimeters (0.020 inches). In more particular embodiments,abrasive material 68 is applied toblade tip 64 so that it has a thickness between about 0.10 millimeters (0.004 inches) and about 0.305 millimeters (0.012 inches). - The disclosed ESD method can provide
blade tip 64 withabrasive material 68 having a roughened surface. A roughened surface reduces the number of contact points betweenblade tip 64 andabradable material 66, thereby reducing the surface temperatures whileblade tip 64 rubsabradable material 66. The reduction in temperature reduces the amount of wear onabrasive material 68 andblade tip 64. In some embodiments,abrasive material 68 applied toblade tip 64 has a surface roughness (Ra) between about 1.25 micrometers (50 microinches) and about 5 micrometers (200 microinches). The surface roughness ofabrasive material 68 andblade tip 64 can be adjusted by varying the ESD parameters to create a desired wear ratio betweenabrasive material 68 andabradable material 66. In some embodiments, the surface roughness provided toabrasive material 68 creates a volumetric wear ratio ofabrasive material 68 toabradable material 64 between about 1:50 and about 1:500. In one particular embodiment, the surface roughness provided toabrasive material 68 creates a wear ratio ofabrasive material 68 toabradable material 66 of about 1:400. - Forming a ceramic coating on
blade tip 64 according to the disclosed ESD method provides advantages over other deposition techniques. ESD does not require the use of masks needed for thermal spray and plating processes. ESD can also create a roughened ceramic coating on blade tips to reduce blade wear and/or generate a desired wear pattern. While the disclosed ESD method has been described with reference to a compressor blade tip for a gas turbine engine, other components, such as those in industrial gas turbine applications, having an abrasive material can be formed in a similar manner. - The following are non-exclusive descriptions of possible embodiments of the present invention.
- A method for forming a component having an abrasive portion can include forming the component and selectively forming a coating on the component using electric spark deposition to form the abrasive portion.
- The method of the preceding paragraph can optionally include, additionally and/or alternatively, any one or more of the following features, configurations and/or additional components:
- A further embodiment of the foregoing method can include that the component is a blade and that the abrasive portion is located at a blade tip.
- A further embodiment of any of the foregoing methods can include that the coating has a surface roughness (Ra) between about 1.25 micrometers (50 microinches) and about 5 micrometers (200 microinches).
- A further embodiment of any of the foregoing methods can include that the coating has a thickness between about 0.025 millimeters (0.001 inches) and about 0.51 millimeters (0.020 inches).
- A further embodiment of any of the foregoing methods can include that the coating has a thickness between about 0.10 millimeters (0.004 inches) and about 0.305 millimeters (0.012 inches).
- A further embodiment of any of the foregoing methods can include that the coating is selected from the group consisting of alumina, zirconia, chromia, hafnia, ceria, titania, silica and combinations thereof.
- A further embodiment of any of the foregoing methods can include that the coating is selected from the group consisting of silicon carbide, tungsten carbide, titanium carbide, boron carbide, cubic boron nitride, aluminum diboride, diamond and combinations thereof.
- A further embodiment of any of the foregoing methods can include that a metal oxide content of the coating is between about 25% by weight and about 100% by weight.
- A further embodiment of any of the foregoing methods can include that the step of selectively forming the coating on the component using electric spark deposition includes applying a voltage between an electrode containing aluminum, zirconium, chromium, hafnium, cerium, titanium, silicon and combinations thereof and the component and moving the electrode toward the component so that a portion of the electrode is deposited on the component.
- A further embodiment of any of the foregoing methods can include that the coating is formed to provide an abrasive:abradable wear ratio of the abrasive portion of the component to an abradable portion of a stationary component adjacent the component, and wherein the abrasive:abradable wear ratio is between about 1:50 and about 1:500.
- A further embodiment of any of the foregoing methods can include that the abrasive:abradable wear ratio is about 1:400.
- A further embodiment of any of the foregoing methods can include that the abradable portion of a stationary component comprises a CoNiCrAlY or NiCoCrAlY alloy.
- A further embodiment of any of the foregoing methods can include that the coating is formed without use of masking techniques.
- A method for coating a blade tip with an abrasive material can include forming a blade having a tip and depositing a coating on the blade tip using electric spark deposition.
- The method of the preceding paragraph can optionally include, additionally and/or alternatively, any one or more of the following features, configurations and/or additional components:
- A further embodiment of the foregoing method can include that the coating is formed without use of masking techniques.
- A further embodiment of any of the foregoing methods can include that coating comprises alumina, zirconia, chromia, hafnia, ceria, titania, silica and combinations thereof.
- A method can include providing a casing having an inner diameter surface, locating an abradable coating on a portion of the inner diameter surface, providing a blade configured to rotate within the casing and having a blade tip where the blade tip and the inner diameter surface of the casing form a seal, and depositing an abrasive coating on the blade tip using electric spark deposition so that the abrasive coating and abradable coating interact during rotation of the blade within the casing.
- The method of the preceding paragraph can optionally include, additionally and/or alternatively, any one or more of the following features, configurations and/or additional components:
- A further embodiment of the foregoing method can include that the abradable coating comprises a CoNiCrAlY or NiCoCrAlY alloy.
- A further embodiment of any of the foregoing methods can include that the abrasive coating has a thickness between about 0.025 millimeters (0.001 inches) and about 0.51 millimeters (0.020 inches).
- A further embodiment of any of the foregoing methods can include that the abrasive coating comprises alumina, zirconia, chromia, hafnia, ceria, titania, silica and combinations thereof.
- While the invention has been described with reference to an exemplary embodiment(s), it will be understood by those skilled in the art that various changes may be made and equivalents may be substituted for elements thereof without departing from the scope of the invention. In addition, many modifications may be made to adapt a particular situation or material to the teachings of the invention without departing from the essential scope thereof. Therefore, it is intended that the invention not be limited to the particular embodiment(s) disclosed, but that the invention will include all embodiments falling within the scope of the appended claims.
Claims (20)
1. A method for forming a component having an abrasive portion, the method comprising:
forming the component; and
selectively forming a coating on the component using electric spark deposition to form the abrasive portion.
2. The method of claim 1 , wherein the component is a blade, and wherein the abrasive portion is located at a blade tip.
3. The method of claim 1 , wherein the coating has a surface roughness (Ra) between about 1.25 micrometers (50 microinches) and about 5 micrometers (200 microinches).
4. The method of claim 1 , wherein the coating has a thickness between about 0.025 millimeters (0.001 inches) and about 0.51 millimeters (0.020 inches).
5. The method of claim 4 , wherein the coating has a thickness between about 0.10 millimeters (0.004 inches) and about 0.305 millimeters (0.012 inches).
6. The method of claim 1 , wherein the coating is selected from the group consisting of alumina, zirconia, chromia, hafnia, ceria, titania, silica and combinations thereof.
7. The method of claim 1 , wherein the coating is selected from the group consisting of silicon carbide, tungsten carbide, titanium carbide, boron carbide, cubic boron nitride, aluminum diboride, diamond and combinations thereof.
8. The method of claim 1 , wherein a metal oxide content of the coating is between about 25% by weight and about 100% by weight.
9. The method of claim 1 , wherein the step of selectively forming the coating on the component using electric spark deposition, comprises:
applying a voltage between an electrode containing aluminum, zirconium, chromium, hafnium, cerium, titanium, silicon and combinations thereof and the component; and
moving the electrode toward the component so that a portion of the electrode is deposited on the component.
10. The method of claim 1 , wherein the coating is formed to provide an abrasive:abradable wear ratio of the abrasive portion of the component to an abradable portion of a stationary component adjacent the component, and wherein the abrasive:abradable wear ratio is between about 1:50 and about 1:500.
11. The method of claim 10 , wherein the abrasive:abradable wear ratio is about 1:400.
12. The method of claim 10 , wherein the abradable portion of a stationary component comprises a CoNiCrAlY or NiCoCrAlY alloy.
13. The method of claim 1 , wherein the coating is formed without use of masking techniques.
14. A method for coating a blade tip with an abrasive material, the method comprising:
forming a blade having a tip; and
depositing a coating on the blade tip using electric spark deposition.
15. The method of claim 14 , wherein the coating is formed without use of masking techniques.
16. The method of claim 14 , wherein the coating comprises alumina, zirconia, chromia, hafnia, ceria, titania, silica and combinations thereof.
17. A method comprising:
providing a casing having an inner diameter surface;
locating an abradable coating on a portion of the inner diameter surface;
providing a blade configured to rotate within the casing and having a blade tip, wherein the blade tip and the inner diameter surface of the casing form a seal; and
depositing an abrasive coating on the blade tip using electric spark deposition so that the abrasive coating and abradable coating interact during rotation of the blade within the casing.
18. The method of claim 17 , wherein the abradable coating comprises a CoNiCrAlY or NiCoCrAlY alloy.
19. The method of claim 17 , wherein the abrasive coating has a thickness between about 0.025 millimeters (0.001 inches) and about 0.51 millimeters (0.020 inches).
20. The method of claim 17 , wherein the abrasive coating comprises alumina, zirconia, chromia, hafnia, ceria, titania, silica and combinations thereof.
Priority Applications (2)
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US14/630,965 US20170016454A1 (en) | 2015-02-25 | 2015-02-25 | Method for coating compressor blade tips |
EP16157300.1A EP3061849A1 (en) | 2015-02-25 | 2016-02-25 | Method for coating compressor blade tips |
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US14/630,965 US20170016454A1 (en) | 2015-02-25 | 2015-02-25 | Method for coating compressor blade tips |
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CN111020572A (en) * | 2019-10-31 | 2020-04-17 | 山东大学 | Electric spark deposition diamond wire saw wire production device |
CN111850554A (en) * | 2020-08-10 | 2020-10-30 | 湖南人文科技学院 | NbC-reinforced large-thickness nanocrystalline wear-resistant coating and preparation method thereof |
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US11346232B2 (en) * | 2018-04-23 | 2022-05-31 | Rolls-Royce Corporation | Turbine blade with abradable tip |
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CN106521393B (en) * | 2016-11-22 | 2018-10-19 | 常州大学 | A kind of coating production and device based on spark discharge |
CN109695049A (en) * | 2019-01-25 | 2019-04-30 | 西京学院 | A kind of metal or alloy surface covering and its preparation method and application |
US11541516B2 (en) | 2019-09-25 | 2023-01-03 | Snap-On Incorporated | Fastener retention and anti-camout tool bit |
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US11143042B2 (en) * | 2014-02-11 | 2021-10-12 | Raytheon Technologies Corporation | System and method for applying a metallic coating |
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