An abrasive coating and a process for forming the abrasive coating by co-depositing hard particles within a matrix material onto a substrate using a cold spray process. The cold sprayed combination of hard particles and matrix material provides a coating that is wear, erosion and oxidation resistant. The abrasive coating may have different compositions across its depth. The hard particles may be deposited at different densities across the thickness of the matrix material. A first layer of the abrasive coating proximate the surface of the substrate may be devoid of hard particles.

Mixed powder deposition of components for wear, erosion and abrasion resistant applications

The present invention relates to a method an apparatus for fabricating a component by a direct laser process One form of the present invention contemplates a gas turbine engine blade having an abrasive tip formed directly thereon

Method and apparatus for making components by direct laser processing

A turbine blade includes a hollow airfoil extending from an integral dovetail. The airfoil includes sidewalls extending between leading and trailing edges and longitudinally between a root and a tip. The sidewalls are spaced apart to define a flow channel for channeling cooling air through the airfoil. The tip is tapered longitudinally above at least one of the sidewalls and decreases in thickness.

Tapered tip turbine blade

A process is provided for producing an abrasive coating on a substrate (14) surface by applying a bond coat (15) by low pressure plasma spraying and anchoring to the bond coat (15) abrasive particles (17) by electroplating and embedding the particles (17) into an oxidation resistant matrix by entrapment plating.

Method for producing abrasive tips for gas turbine blades

An actively cooled TBC bond coat wherein active convection cooling is provided through micro channels inside or adjacent to a bond coat layer applied to a substrate. The micro channels communicate directly with at least one cooling fluid supply contained within a turbine engine component, thereby providing direct and efficient cooling for the bond coat layer. Because the substrate is covered with an actively cooled bond coat layer, it will reduce the cooling requirement for the substrate, thus allowing the engine to run at higher operating temperature without the need for additional cooling air, achieving a better engine performance. In one form, the component includes a substrate having at least one substrate channel with a first and second end. At least one micro channel is in fluid communication with a plenum which in turn is in fluid communication with at least one substrate channel through an exit orifice in the substrate channel which is at a first end of the substrate channel. A second end of the substrate channel is in communication with a cooling fluid supply, for example, cooling circuits contained within the turbine engine component. The micro channel is located between the substrate surface and the outer gas flow path surface of the component.

Directly cooled thermal barrier coating system

A method and apparatus for increasing blade fatigue strength in a turbine engine. The blades in the turbine engine are configured so as to reduce stress at the tip of the blades during operation of the turbine engine, thus increasing blade fatigue strength. This stress reduction helps to counteract the detrimental effect of abrasive tip coatings on blade fatigue strength. In one embodiment, the tip of the blade is chamfered in order to reduce the stress on the tip of the blade. An abrasive coating is then applied to the tip of the blade to assist the blade in seating into an abradable outer air seal. In another embodiment, an abrasive coating is applied to a center portion of the tip of the blade, with the periphery of the abrasive coating being set back from the opposing surfaces of the blade.

Method and apparatus for reducing stress on the tips of turbine or compressor blades

The blades 20 in the turbine engine are configured so as to reduced stress at the tip of the blades during operation of the turbine engine, thus helping to counteract the detrimental effect of abrasive tip coatings on blade fatigue strength. In one embodiment, the tip of the blade 20 is chamfered 30 in order to reduce the stress on the tip of the blade. An abrasive coating is then applied to the tip of the blade to assist the blade in seating into an abradable outer air seal. In another embodiment, (figs. 10, 11) an abrasive coating (68) is applied to a center portion of the tip of the blade, with the periphery of the abrasive coating being set back from the opposing surfaces of the blade.

Reducing stress on the tips of turbine or compressor blades

The present invention relates to a method and apparatus for forming abrasive surfaces on the tips of a plurality of workpieces such as the tips of gas turbine airfoil blades. The method broadly comprises the steps of providing a mechanical masking device having a plurality of openings arranged around the circumference of the device, installing an array containing a plurality of workpieces to be coated within the mechanical masking device so that portions of the workpieces including the tips thereof extend through the openings, immersing the mechanical masking device with the installed array of workpieces in a tank containing a plating bath with a matrix material and an abrasive grit material in slurry form so that the workpieces lie in a substantially horizontal plane, and applying a current through the plating bath to form the abrasive surfaces on the tips of the workpieces. The mechanical masking device protects portions of the array from the coating operation. A barrier device is also used to confine the abrasive grit material within a desired space during the formation of the abrasive coating on the tip portions.

Method for abrasive tipping of integrally bladed rotors

The present invention relates to a method and apparatus for forming abrasive surfaces on the tips of a plurality of workpieces such as the tips of gas turbine airfoil blades. The method broadly comprises the steps of providing a mechanical masking device having a plurality of openings arranged around the circumference of the device, installing an array containing a plurality of workpieces to be coated within the mechanical masking device so that portions of the workpieces including the tips thereof extend through the openings, immersing the mechanical masking device with the installed array of workpieces in a tank containing a plating bath with a matrix material and an abrasive grit material in slurry form so that the workpieces lie in a substantially horizontal plane, and applying a current through the plating bath to form the abrasive surfaces of the tips of the workpieces. The mechanical masking device protects portions of the array form the coating operation. A barrier device is also used to confine the abrasive grit material within a desired space during the formation of the abrasive coating on the tip portions.

Gary A Gruver

Papers

Method and apparatus for reducing stress on the tips of turbine or compressor blades

Reducing stress on the tips of turbine or compressor blades

Method for abrasive tipping of integrally bladed rotors

Apparatus for abrasive tipping of integrally bladed rotors

Method for CBN tipping of HPC integrally bladed rotors