Direct deposition of metallic coating

Patent metadata

Field	Value
Publication number	US-2016167180-A1
Application number	US-201514965050-A
Country	US
Kind code	A1
Filing date	Dec 10, 2015
Priority date	Dec 15, 2014
Publication date	Jun 16, 2016
Grant date	—

Abstract

A method for coating a part according to an aspect of the disclosure includes the step binding a metallic powder to a section of the part. The metallic powder is then energized which at least partially melts and resolidifies the metallic powder to form a first metallic coating. After the first layer of metallic coating is formed a second layer of metallic coating is deposited on substantially all of the part.

First claim

1 . A method for coating a part, comprising:
binding a metallic powder to a section of the part; energizing the metallic powder to at least partially melt and resolidify the metallic powder to form a first metallic coating; and depositing a second metallic coating to substantially all of the part.

2 . The method of claim 1 , wherein the binding includes applying a binder to the part.

3 . The method of claim 2 , wherein the binding includes depositing the metallic powder on the binder.

4 . The method of claim 2 , wherein the binder has at least one of a protein, starch, and a sugar suspended or dissolved therein.

5 . The method of claim 4 , wherein the protein is gluten.

6 . The method of claim 1 , wherein the metallic powder comprises a nickel- or cobalt-based alloy.

7 . The method of claim 1 , wherein the metallic powder is bound to the section of the part by spraying the powder onto the section of the part.

8 . The method of claim 1 , wherein the part is a first vane of a vane cluster having a plurality of vanes.

9 . The method of claim 8 , wherein the section of the first vane is an inboard surface of the first vane that is shadowed by a second vane of the vane cluster.

10 . The method of claim 1 , wherein the second metallic coating has a first thickness on a first section of the part and a second thickness different from the first thickness on a second section of the part.

11 . The method of claim 1 , wherein a contact metal deposition process energizes the metallic powder.

12 . The method of claim 11 , wherein the contact metal deposition process is an electro-spark deposition process which utilizes an electrode and comprises:
applying a first voltage to the electrode; applying a second voltage to the part, wherein the first voltage is greater than the second voltage; and touching the electrode to the section of the part, wherein a microstructure of the part is substantially unaltered by the electro-spark deposition process.

13 . The method of claim 12 , wherein the electrode comprises a nickel- or cobalt-based alloy and supplies a portion of the metallic coating.

14 . The method of claim 1 , wherein the step of depositing the second metallic coating to substantially all of the part is performed using a process selected from a group consisting of: low pressure plasma spray, electron beam physical vapor deposition, air spray, electron beam directed vapor deposition, and combinations thereof.

15 . The method of claim 1 , wherein the metallic powder is energized to form a first metallic coating on the section of the part before the second metallic coating is deposited to substantially all of the part.

16 . A method of coating a vane, comprising:
binding a metallic powder to an inboard surface of the vane that is shadowed by a second vane of a vane cluster; energizing the metallic powder to at least partially melt and resolidify the metallic powder to form a first metallic coating with a desired thickness on the shadowed inboard surface of the vane; and depositing a second metallic coating to substantially all of the vane such that the first and second metallic coatings together provide a substantially uniform coating to the vane.

17 . The method of claim 16 , wherein the second metallic coating has a first thickness on a surface of the vane that is not shadowed and a second thickness different from the first thickness on the shadowed surface of the vane.

18 . The method of claim 17 , wherein the first thickness of the second metallic coating is equal to the sum of the second thickness of the second metallic coating and a third thickness of the first layer of metallic coating.

19 . The method of claim 16 , wherein the step of binding the metallic powder includes first depositing a binder to the shadowed surface of the vane followed by depositing the metallic powder on the binder.

20 . The method of claim 16 , wherein the metallic powder is energized using an electro-spark deposition process and comprises the steps of:
applying a first voltage to an electrode; applying a second voltage to the vane, wherein the first voltage is greater than the second voltage; and touching the electrode to the shadowed surface of the vane wherein a microstructure of the vane is substantially unaltered by the electro-spark deposition process.

Assignees

• United Technologies Corp

Inventors

• Thayer Henry H
• Whitman Giovanni
• Larson Gary J
• Lin Wangen

Classifications

• C23C24/106

  Coating with metal alloys or metal elements only · CPC title

• C23C28/022

  with at least one MCrAlX layer · CPC title

• B22F1/17 Primary

  Metallic particles coated with metal · CPC title

• B23P6/007 Primary

  using only additive methods, e.g. build-up welding · CPC title

• B22F1/025

  Operations & Transport · mapped topic