Substrate edge configurations for ceramic coatings

Patent metadata

Field	Value
Publication number	US-11920478-B2
Application number	US-202117385003-A
Country	US
Kind code	B2
Filing date	Jul 26, 2021
Priority date	Nov 8, 2018
Publication date	Mar 5, 2024
Grant date	Mar 5, 2024

Abstract

In a method for manufacturing an article, the article has a body having: a first face; and a first bevel surface extending from the first face. A plurality of first channels along the first bevel surface extending from the first face. A ceramic coating is along the inner diameter surface and the first bevel surface. Each of the first channels are machined in the body by plunging a rotating bit into the first surface and drawing the rotating bit down the bevel surface. The coating is thereafter applied.

First claim

What is claimed is:

1. A method for manufacturing an article, the article comprising:
a body having:
a first face; and
a first bevel surface extending from the first face; and
a plurality of first channels along the first bevel surface extending from the first face; and

a ceramic coating along the first face and the first bevel surface,

the method comprising:
machining each of the first channels in the body by:
plunging a rotating bit into the first face; and
drawing the rotating bit down the first bevel surface; and

applying the coating.

2. The method of claim 1 wherein the article is a gas turbine engine component.

3. The method of claim 1 wherein:
the ceramic coating comprises a stabilized zirconia.

4. The method of claim 1 wherein:
the body is metallic.

5. The method of claim 4 wherein:
the body comprises a metallic substrate and a metallic bondcoat.

6. The method of claim 5 wherein:
the metallic substrate is a nickel-based superalloy; and
the ceramic coating comprises a stabilized zirconia.

7. The method of claim 1 wherein:
the body has:
a plurality of first recesses in a pattern along the first face;

the first channels comprise a first group of channels and a second group of channels:
the channels of the first group being of different size than the channels of the second group; and
the channels of the first group being of different registry with the pattern than are the channels of the second group.

8. The method of claim 7 wherein:
the pattern along the first face is a hexagonal array; and
the hexagonal array has a first row along the first bevel surface;
the channels of the first group are longer than the channels of the second group;
the channels of the first group are in-phase with the recesses of the first row; and
the channels of the second group are out-of-phase with the recesses of the first row.

9. The method of claim 7 further comprising:
plunge end milling to form the plurality of first recesses in the pattern along the first face.

10. The method of claim 1 wherein the article is a blade outer airseal wherein:
the first face is a transversely concave inner diameter surface;
the body comprises:
a first circumferential end;
a second circumferential end;
a first axial end;
a second axial end;
said first bevel surface between the first circumferential end and the inner diameter surface;
a second bevel surface between the second circumferential end and the inner diameter surface;
said plurality of first channels along the first bevel surface extending from the inner diameter surface to the first circumferential end; and
a plurality of second channels along the second bevel surface extending from the inner diameter surface to the second circumferential end; and

said ceramic coating along the inner diameter surface, the first bevel surface, and the second bevel surface.

11. The method outer airseal of claim 10 wherein:
the body has:
a plurality of first recesses along the inner diameter surface.

12. The method outer airseal of claim 10 wherein:
the ceramic has a by weight majority of at least one of YSZ and GSZ.

13. The method of claim 1 wherein:
the first bevel surface is at first circumferential end of the body; and
the body has a second circumferential end and a second bevel surface extending from the first face to the second circumferential end.

14. The method of claim 1 further comprising:
grinding the coating to remove artifacts of the first channels.

15. The method of claim 1 wherein the machining each of the first channels further comprises:
between the plunging and the drawing, turning the bit transverse to its rotation.

16. The method of claim 9 wherein:
the plunge end milling is with a first said rotating bit used for said machining of each of the first group of first channels; and
said machining of the second group of first channels is with a second said rotating bit smaller than the first said rotating bit.

17. The method of claim 16 wherein the machining each of the first channels further comprises:
between the plunging and the drawing, turning the bit transverse to its rotation.

18. The method of claim 17 wherein:
the ceramic coating comprises a stabilized zirconia and is applied by air plasma spray.

Assignees

• Raytheon Tech Corp
• Rtx Corp

Inventors

• Strock Christopher W

Classifications

• F23R2900/03044

  Impingement cooled combustion chamber walls or subassemblies · CPC title

• B23P15/04

  turbine or like blades from several pieces · CPC title

• F05D2230/14

  Micromachining · CPC title

• F05D2250/191

  perforated · CPC title

• F05D2250/192

  bevelled · CPC title