Substrate features for mitigating stress
AssigneeROLLS-ROYCE plc
InventorsAnn Bolcavage, Raymond J. Sinatra
Life of this patent
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Abstract
An article may include an array of features formed in a substrate and may be coated with a coating layer. The array of features may mitigate stress experienced by the coated article. In particular, the array of features may reduce or limit crack propagation at the interface between the substrate and the coating layer. In some examples, the article is an airfoil that includes a tip that defines an edge. An array of features is formed on the surface of the tip, where the array of features is proximate to the edge, and the array of features does not intersect the edge. The airfoil includes a coating layer formed on the surface of the tip and the array of features.
Claims31
An airfoil comprising:
- a tip that defines an edge;
- a patterned array of features on a surface of the tip, wherein the patterned array of features is proximate to the edge, and wherein none of the features on the surface of the tip intersect the edge and each of the features on the surface of the tip is at least 0.254 millimeters from the edge;
- and
- an abrasive coating on the surface of the tip and the patterned array of features and extending over substantially all of the tip to the edge of the tip.
An airfoil comprising:
- a tip that defines an edge;
- a first patterned array of features on a surface of the tip at a first location, wherein the first patterned array comprises a first pattern;
- a second patterned array of features on a surface of the tip at a second location wherein the second patterned array comprises a second pattern different than the first pattern, wherein the first location is predicted to experience a first level of stress and the second location is predicted to experience a second level of stress different than the first level of stress;
- and
- an abrasive coating on the tip, the first patterned array of features, and the second patterned array of features, wherein the abrasive coating extends over substantially all of the tip to the edge of the tip, and wherein none of the features on the surface of the tip intersect the edge and each of the features on the surface of the tip is at least 0.254 millimeters from the edge.
A method comprising:
- forming a patterned array of features on a tip surface of a tip of an airfoil that defines an edge, wherein the patterned array of features is proximate to the edge, and wherein none of the features on the surface of the tip intersect the edge and each of the features on the surface of the tip is at least 0.254 millimeters from the edge;
- and
- forming an abrasive coating on the tip surface and the patterned array of features and extending over substantially all of the tip surface to the edge of the tip.
Dependencies are inferred from the claim text.