Method for forming a channel on the surface of a metal substrate
AssigneeGeneral Electric Company
InventorsWayne Charles Hasz, Venkat S. Venkataramani, Ching-Pang Lee
Life of this patent
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Abstract
A method for forming a channel within a coated, metal-based substrate is described. In one technique, a channel-forming material is first deposited on the substrate, followed by the deposition of a bonding agent, such as a braze. One or more coatings can then be applied over the substrate. In one embodiment, the channel is formed when the channel-forming material is subsequently removed. In another embodiment, the channel is formed due to the lack of adhesion between particular channel-forming materials and the overlying bonding agent. Related articles are also described, e.g., gas turbine components which include protective coatings and a pattern of cooling channels.
Claims46
A method for forming at least one channel within a coated, metal-based substrate, comprising the following steps:
- (a) depositing a channel-forming material on an unpatterned portion of a surface of the substrate, in a pattern which represents a selected shape for the channel;
- then
- (b) applying and fusing a desired coating material to the surface with an underlying bonding agent, so that the bonding agent fills in the spaces defined by the channel-forming material and the coating covers the channel-forming material and a selected area of the surface;
- and then
- (c) removing the channel-forming material, so as to form the channel.
A method for forming at least one channel within a coated, metal-based substrate, comprising the following steps:
- (a) depositing a channel-forming material on a surface of the substrate, in a pattern which represents a selected shape for the channel, wherein the channel-forming material is in the form of a free-standing foil which is attached to the substrate surface;
- (b) fusing a desired coating material to the surface with an underlying bonding agent, so that the coating covers the channel-forming material and a selected area of the surface;
- and
- (c) removing the channel-forming material, so as to form the channel.
A method for forming at least one channel within a coated, metal-based substrate, comprising the following steps:
- (a) depositing a channel-forming material on a surface of the substrate, in a pattern which represents a selected shape for the channel;
- (b) fusing a desired coating material to the surface with an underlying bonding agent, so that the coating covers the channel-forming material and a selected area of the surface, wherein the bonding agent and the channel-forming material are in the form of a free-standing bilayer foil which is attached to the substrate, said bilayer comprising a lower sublayer of the channel-forming material and an upper sublayer of the bonding agent;
- and
- (c) removing the channel-forming material, so as to form the channel.
A method for forming cooling channels within a superalloy substrate covered by a metallic bond coat and an overlying thermal barrier coating, comprising the following steps:
- (I) attaching a free-standing bilayer foil to a surface of the substrate, said bilayer comprising a lower sublayer of a channel-forming material and an upper sublayer of a braze material, wherein the bilayer has a shape which represents a selected shape for the cooling channels, and the lower sublayer contacts a pre-selected area of the substrate surface;
- (II) fusing the bond coat and the thermal barrier coating to the substrate surface with the braze material, so that the bond coat and the thermal barrier coating cover the channel-forming material and the pre-selected area of the substrate surface;
- and then
- (III) removing the channel-forming material, so as to form the desired channels.
A method for forming a channel within a coated, metal-based substrate, comprising the following steps:
- (A) depositing a channel-forming material on the surface of the substrate, in a pattern which represents a selected shape for the channel, wherein the channel-forming material is capable of preventing adhesion between the substrate and a bonding agent applied over the substrate and the channel-forming material;
- and
- (B) fusing a desired coating to the substrate with the bonding agent, so that the coating covers the channel-forming material and a selected area of the substrate, and the bonding agent which underlies the coating does not substantially adhere to the channel-forming material, thereby forming a channel.
Dependencies are inferred from the claim text.