Abrasive tip blade manufacture methods

Patent metadata

Field	Value
Publication number	US-11732595-B2
Application number	US-201916658690-A
Country	US
Kind code	B2
Filing date	Oct 21, 2019
Priority date	Apr 15, 2015
Publication date	Aug 22, 2023
Grant date	Aug 22, 2023

Abstract

A blade comprises an airfoil having a root end and a tip. A metallic substrate is along at least a portion of the airfoil. An abrasive tip coating comprises an abrasive and an aluminum-based matrix. An aluminum-based base layer is between the tip coating and the substrate.

First claim

What is claimed is:

1. A blade comprising:
an airfoil having:
a root end and a tip;
a metallic substrate along at least a portion of the airfoil; and
an abrasive tip coating comprising an abrasive and an aluminum-based matrix; and
an aluminum-based base layer between the tip coating and the substrate, wherein the matrix and base layer are pure aluminum,

wherein:
the substrate comprises, by weight percent:
<=0.3 Cr;
1.0-4.5 Cu;
<=0.15 Fe;
<=3.0 Li;
0.05-3.0 Mg;
<=0.6 Mn;
<=0.4 Si;
<=1.0 Ag;
<=0.25 Ti;
0.1-10.0 Zn;
<=0.25 Zr; and
balance Al with <=0.05 other, each, and <=0.15 other, total; and

at least one of:
the base layer is softer than the substrate; and
the base layer has a yield strength less than a yield strength of the substrate.

2. The blade of claim 1 wherein the base layer is free of the abrasive.

3. The blade of claim 1 wherein:
the matrix and the base layer are softer than the substrate.

4. The blade of claim 1 wherein the substrate comprises, by weight percent:
<=0.05 Cr;
2.0-4.5 Cu;
<=0.09 Fe;
<=2.0 Li;
0.1-2.3 Mg;
0.10-0.50 Mn;
<=0.07 Si;
<=0.50 Ag;
<=0.10 Ti;
0.3-8.4 Zn;
0.05-0.15 Zr; and
balance Al with <=0.05 other, each, and <=0.15 other, total.

5. The blade of claim 4 further comprising:
a polymeric coating on a pressure side and a suction side of the airfoil.

6. The blade of claim 1 further comprising:
a polymeric coating on a pressure side and a suction side of the airfoil.

7. A method for manufacturing the blade of claim 1 , the method comprising:
simultaneous spraying of the matrix and the abrasive; and
prior to the simultaneous spraying, spraying the base layer atop the substrate.

8. The method of claim 7 wherein the abrasive is a non-oxide abrasive.

9. The method of claim 7 wherein:
the abrasive tip coating has a content of the abrasive of at least ten volume percent.

10. The method of claim 7 wherein:
the abrasive fills the matrix to at least 10 volume percent.

11. The method of claim 7 wherein:
the tip coating has a characteristic thickness of 0.1 mm to 0.3 mm.

12. The method of claim 7 wherein:
the abrasive has a characteristic size of 30 micrometers to 200 micrometers.

13. The method of claim 7 further comprising:
applying a polymeric coating to a pressure side and a suction side of the airfoil.

14. A method for using the blade of claim 1 , the method comprising:
causing the tip coating to abrade an adjacent coating.

15. A rotor comprising a circumferential array of blades of claim 1 .

16. A gas turbine engine comprising:
the rotor of claim 15 ; and
a case encircling the rotor and having:
a substrate; and
a coating on an inner surface of the substrate facing the rotor.

Assignees

• Raytheon Tech Corp

Inventors

• Strock Christopher W

Classifications

• F01D5/288 Primary

  Protective coatings for blades · CPC title

• F01D5/147

  Construction, i.e. structural features, e.g. of weight-saving hollow blades (F01D5/148, F01D5/16 and F01D5/20 take precedence; blade shape F01D5/141; blades with cooling or heating channels or cavities F01D5/18; heating, heat-insulating or cooling means on blades F01D5/18) · CPC title

• F01D11/122 Primary

  with erodable or abradable material (blades having cutting or grinding tips F01D5/20) · CPC title

• F01D25/24

  Casings (modified for heating or cooling F01D25/14); Casing parts, e.g. diaphragms, casing fastenings (casings for rotary machines or engines in general F16M {; special arrangements in stators dealing with breaking-off of part of rotor F01D21/045}) · CPC title

• F04D29/023

  especially adapted for elastic fluid pumps · CPC title