Systems and Methods for Optimal Source Material Deposition Along Hole Edges

Patent metadata

Field	Value
Publication number	US-2016251753-A1
Application number	US-201514632158-A
Country	US
Kind code	A1
Filing date	Feb 26, 2015
Priority date	Feb 26, 2015
Publication date	Sep 1, 2016
Grant date	—

Abstract

A method for depositing a coating of a source material onto a panel is disclosed. The method includes providing a cathodic arc, the cathodic arc including a target surface, the target surface disposed along a target deposition axis and able to emit the source material as a generally cloud of source material vapor and a generally conical stream of liquid particles of the source material. The method further includes positioning the panel relative to the target surface based on a deposition angle, the deposition angle being between the target surface and an outer limit of the generally conical stream of liquid particles o the source material. The method may further include emitting the source material from the target surface as the generally conical cloud of source material vapor and coating the edge with the cloud of source material vapor to provide an edge coating.

First claim

What is claimed is:

1 . A method for depositing a coating of a source material onto a panel, the panel defining an edge and a front panel surface, the method comprising:
providing a cathodic arc, the cathodic arc including a target surface, the target surface disposed along a target deposition axis and able to emit the source material as both a cloud of source material vapor and a generally conical stream of liquid particles of the source material; positioning the panel relative to the target surface based on a deposition angle, the deposition angle being between the target surface and an outer limit of the generally conical stream of liquid particles of the source material; emitting the source material from the target surface as the cloud of source material vapor and the generally conical stream of liquid particles of the source material; and coating the edge with the cloud of source material vapor to provide an edge coating.

2 . The method of claim 1 , wherein positioning the panel relative to the target surface based on the deposition angle includes positioning the panel substantially perpendicular to the target deposition axis.

3 . The method of claim 1 , wherein the panel defines at least one hole,
wherein the edge is a hole edge of the at least one hole, and wherein coating the edge with the cloud of source material vapor to provide an edge coating includes coating the hole edge of the at least one hole.

4 . The method of claim 3 , wherein the target deposition axis defines a target deposition plane, and
wherein positioning the panel relative to the target surface based on the deposition angle includes positioning the panel such that the at least one hole is disposed above the target deposition plane.

5 . The method of claim 3 , wherein the target deposition axis defines a target deposition plane, and
wherein positioning the panel relative to the target surface based on the deposition angle includes positioning the panel such that the at least one hole is disposed below the target deposition plane.

6 . The method of claim 1 , further comprising coating the front panel surface with the source material to provide a front panel surface coating.

7 . The method of claim 2 , wherein coating the edge with the source material to provide the edge coating deposits the edge coating at an edge density;
wherein coating the front panel surface with the source material to provide the front panel surface coating deposits the front panel surface coating at a front panel surface density; and wherein the edge density and the front panel surface density are substantially similar.

8 . The method of claim 2 , wherein emitting the source material from the target surface further includes emitting an oxidation resistant material as the source material.

9 . The method of claim 1 , wherein emitting the source material from the target surface further includes emitting a MCrAIY-type material as the source material.

10 . The method of claim 1 , further comprising electrically charging the cathodic arc and wherein emitting the source material from the target surface occurs in response to the electrically charging of the cathodic arc.

11 . The method of claim 1 , further comprising electrically charging the panel such that a negative charge attracts the source material to at least one of the edge and the front panel surface.

12 . A system for depositing a coating of a source material onto at least one panel, the at least one panel defining an edge and a front panel surface, the system comprising:
a cathodic arc including a target surface, the target surface disposed along a target deposition axis, and able to emit the source material as both a cloud of source material vapor and a generally conical stream of liquid particles of the source material, the cloud of source material vapor used to coat the edge with the source material to provide an edge coating; and a coating deposition structure, the coating deposition structure positioning one or both of the cathodic arc and the panel, such that the panel is positioned relative to the target surface based on a deposition angle, the deposition angle being between the target surface and an outer limit of the generally conical stream of liquid particles of the source material.

13 . The system of claim 12 , wherein the coating deposition structure positions the panel substantially perpendicular to the target deposition axis.

14 . The system of claim 12 , wherein the panel defines at least one hole, the edge is a hole edge of the at least one hole, and the edge coating is a hole edge coating.

15 . The system of claim 14 , wherein the target deposition axis defines a target deposition plane, and
wherein positioning the panel relative to the target surface based on the deposition angle includes positioning the panel such that the at least one hole is disposed above the target deposition plane.

16 . The method of claim 14 , wherein the target deposition axis defines a target deposition plane, and
wherein positioning the panel relative to the target surface based on the deposition angle includes positioning the panel such that the at least one hole is disposed below the target deposition plane.

17 . A method for depositing a coating of a source material onto a combustor panel of a combustor section of a gas turbine engine, the combustor panel defining a plurality of holes and a front panel surface, each of the plurality of holes including a hole edge, the method comprising:
providing a cathodic arc, the cathodic arc including a target surface, the target surface disposed along a target deposition axis and able to emit the source material as a cloud of source material vapor and as a generally conical stream of liquid particles of the source material; positioning the combustor panel relative to the target surface based on a deposition angle, the deposition angle being between the target surface and an outer limit of the generally conical stream of liquid particles of the source material; emitting the source material from the target surface as the generally conical cloud of source material vapor and the generally conical stream of liquid particles of the source material; and coating each hole edge with the cloud of source material vapor to provide hole edge coatings.

18 . The method of claim 17 , wherein positioning the combustor panel relative to the target surface based on the deposition angle includes positioning the combustor panel substantially perpendicular to the target deposition axis.

19 . The method of claim 17 , wherein the target deposition axis defines a target deposition plane, and
wherein positioning the combustor panel relative to the target surface based on the deposition angle includes positioning the combustor panel such that the at least one of the plurality of holes is disposed above the target deposition plane.

20 . The method of claim 17 , wherein the target deposition axis defines a target deposition plane, and
wherein positioning the panel relative to the target surface based on the deposition angle includes positioning the combustor panel such that the at least one of the plurality of holes is disposed below the target deposition plane.

Assignees

• United Technologies Corp

Inventors

• Task Michael
• Beers Russell

Classifications

• F23R3/002

  Wall structures (F23R3/02 and F23R3/007 take precedence) · CPC title

• C23C14/14

  Metallic material, boron or silicon · CPC title

• C23C14/325 Primary

  Electric arc evaporation · CPC title

• H01J37/32614

  Consumable cathodes for arc discharge · CPC title

• F23R2900/00018

  Manufacturing combustion chamber liners or subparts · CPC title