System and method for applying abrasive grit

Patent metadata

Field	Value
Publication number	US-2018216237-A1
Application number	US-201715419705-A
Country	US
Kind code	A1
Filing date	Jan 30, 2017
Priority date	Jan 30, 2017
Publication date	Aug 2, 2018
Grant date	—

Abstract

A method for forming an abrasive surface includes utilizing an energy source to form a melt pool layer in a substrate and applying abrasive grit into the melt pool layer. A method for forming an abrasive surface including applying an abrasive grit to a substrate and utilizing an energy source to form a melt pool layer in the substrate without disturbing the abrasive grit such that the abrasive grit becomes embedded in the melt pool layer.

First claim

1 . A method for forming an abrasive surface, comprising:
utilizing an energy source to form a melt pool into a substrate; and applying an abrasive grit into the melt pool, the melt pool of a thickness less than the grit size of the abrasive grit.

2 . The method as recited in claim 1 , wherein the abrasive grit includes cubic boron nitride (cBN).

3 . The method as recited in claim 1 , wherein the energy source includes a laser.

4 . The method as recited in claim 1 , wherein the energy source includes magnetic induction.

5 . The method as recited in claim 1 , wherein the melt pool is 20 to 200 μm in depth.

6 . The method as recited in claim 1 , wherein the substrate is an airfoil.

7 . The method as recited in claim 6 , wherein the substrate is a tip of the airfoil.

8 . The method as recited in claim 1 , wherein applying the abrasive grit includes varying a concentration of the abrasive grit.

9 . The method as recited in claim 1 , wherein applying the abrasive grit includes varying a type of abrasive grit.

10 . The method as recited in claim 1 , wherein applying the abrasive grit includes applying the abrasive grit in a predetermined pattern.

11 . A method for forming an abrasive surface, comprising:
applying an abrasive grit to a substrate; and utilizing an energy source to form a melt pool in the substrate without disturbing the abrasive grit as the abrasive grit does not obscure the energy source such that the abrasive grit becomes partially embedded in the melt pool to form the abrasive surface, the melt pool of a thickness less than the grit size of the abrasive grit.

12 . The method as recited in claim 11 , wherein the abrasive grit includes cubic boron nitride (cBN).

13 . The method as recited in claim 11 , wherein the energy source includes a laser.

14 . The method as recited in claim 11 , wherein the energy source includes magnetic induction.

15 . The method as recited in claim 1 , wherein the melt pool is between about 20 to 200 μm.

16 . The method as recited in claim 11 , wherein the substrate is an airfoil.

17 . The method as recited in claim 16 , wherein the substrate is a tip of the airfoil.

18 . The method as recited in claim 11 , wherein applying the abrasive grit includes varying a concentration of the abrasive grit.

19 . The method as recited in claim 11 , wherein applying the abrasive grit includes varying a type of abrasive grit.

20 . The method as recited in claim 11 , wherein applying the abrasive grit includes applying the abrasive grit in a predetermined pattern via a computer aided manufacturing system.

21 . The method as recited in claim 1 , wherein abrasive grit becomes partially embedded in the melt pool.

22 . The method as recited in claim 1 , wherein the melt pool is 20 to 200 μm in depth and the size of the abrasive grit is between 10 μm up to about 200 μm such that the abrasive grit extends at least partially above the melt pool.

23 . The method as recited in claim 1 , wherein the melt pool is 10 microns deep and the grit particle size is 200 microns.

24 . The method as recited in claim 1 , further comprising:
adding metal powder onto the substrate around the abrasive grit; and melting the metal powder in place to increase retention of the abrasive grit such that the abrasive grit extends to form the abrasive surface.

Assignees

• United Technologies Corp

Inventors

• Viens Daniel V
• Humbert Michael Paul
• Mantese Joseph V
• Kountanya Raja

Classifications

• C23C24/10 Primary

  with intermediate formation of a liquid phase in the layer · CPC title

• F05D2240/305

  related to the pressure side of a rotor blade · CPC title

• F05D2230/30

  with deposition of material · CPC title

• F05D2240/303

  related to the leading edge of a rotor blade · CPC title

• F05D2220/32

  in gas turbines · CPC title