Applying bond coat to engine components using cold spray
AssigneeUnited Technologies Corporation
InventorsAndrew DeBiccari, Melvin Freling, Jeffrey Haynes
Life of this patent
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Abstract
A process for applying a coating to a component used in an engine is provided. The process includes the steps of providing a component with at least one surface to be coated, and depositing at least one layer of powder coating material onto the at least one surface using a non-oxidizing carrier gas so that the powder coating material plastically deforms without melting and bonds to the at least one surface upon impact with the at least one surface. The process of the present invention has particular utility in applying bond coats to airfoil portions of turbine blades or vanes and to applying bond coats to combustion chamber liners.
Claims47
1-2. (canceled)
The process according to claim 24, wherein said depositing step comprises providing said powder coating material in particle form having a particle size no greater than 10 microns.
(canceled)
The process according to claim 24, wherein said depositing step comprises forming a bond coat having a bond strength in the range up to 10 ksi or greater.
The process according to claim 24, wherein said depositing step comprises depositing a MCrAlY material on said component where M is at least one of nickel and cobalt.
The process according to claim 24, wherein said depositing step comprises depositing a coating which is at least 97% dense on said component.
A process for applying a coating to a component comprising the steps of:
- providing a component having at least one surface to be coated;
- said component providing step comprises providing a combustion chamber liner formed from a nickel-based alloy or a copper based alloy;
- depositing at least one layer of a powder coating material onto said at least one surface using a non-oxidizing carrier gas so that said powder coating material plastically deforms without melting and bonds to said at least one surface upon impact with said at least one surface;
- and
- said depositing step comprises depositing said at least one layer on at least one surface of said combustion chamber liner.
A process for applying a coating to a component comprising the steps of:
- providing a component having at least one surface to be coated;
- said component providing step comprises providing an engine component having an airfoil surface and a plurality of cooling holes in a said surface;
- depositing at least one layer of a powder coating material onto said at least one surface using a non-oxidizing carrier gas so that said powder coating material plastically deforms without melting and bonds to said at least one surface upon impact with said at least one surface;
- said depositing step comprises depositing said at least one layer of powder coating material without bridging said cooling holes in said surface;
- and
- said depositing step further comprising feeding said powdered coating material to a spray nozzle at a feed rate of from 10 grams/min to 100 grams/min.
Dependencies are inferred from the claim text.