Method for coating a tip of an aerofoil and aerofoil

Patent metadata

Field	Value
Publication number	US-2024093613-A1
Application number	US-202318242816-A
Country	US
Kind code	A1
Filing date	Sep 6, 2023
Priority date	Sep 20, 2022
Publication date	Mar 21, 2024
Grant date	—

Abstract

A method ( 400 ) for coating a tip ( 106 ) of an aerofoil ( 100 ) is provided. The method ( 400 ) includes depositing a layer of nickel-based gamma/gamma prime chemistry ( 112 ) on the tip ( 106 ) of the aerofoil ( 100 ). The method ( 400 ) further includes depositing plurality of abrasive particles ( 114 ) on the layer of nickel-based gamma/gamma prime chemistry ( 112 ) to form a coating matrix ( 116 ). The method ( 400 ) further includes heating the tip ( 106 ) of the aerofoil ( 100 ) at a predetermined temperature in order to perform heat treatment of the coating matrix ( 116 ) and increase the strength of the coating ( 110 ) on the tip ( 106 ) of the aerofoil ( 100 ).

First claim

1 . A method for coating a tip of an aerofoil for a gas turbine engine, the method comprising:
depositing a layer of nickel-based gamma/gamma prime chemistry on the tip of the aerofoil; depositing plurality of abrasive particles on the layer of nickel-based gamma/gamma prime chemistry to form a coating matrix; and heating the tip of the aerofoil at a predetermined temperature in order to perform heat treatment of the coating matrix and increase the strength of the coating on the tip of the aerofoil.

2 . The method of claim 1 , wherein heating the tip of the aerofoil further comprises induction heating of the tip.

3 . The method of claim 1 , wherein heating the tip of the aerofoil further comprises laser heating of the tip.

4 . The method of claim 1 , further comprising cooling an uncoated portion of the aerofoil during the heating of the tip at the predetermined temperature, wherein the cooling of the uncoated portion of the aerofoil maintains a temperature of the uncoated portion below 800° C.

5 . The method of claim 4 , further comprising insulating, via a heat shield, the uncoated portion of the aerofoil from the tip of the aerofoil during the heating of the tip at the predetermined temperature.

6 . The method of claim 1 , wherein depositing the layer of nickel-based gamma/gamma prime chemistry on the tip of the aerofoil further comprises:
depositing a layer of nickel and/or cobalt on the tip of the aerofoil; and depositing a layer of chromium, aluminium, titanium, and/or tantalum on the layer of nickel and/or cobalt.

7 . The method of claim 1 , wherein depositing the layer of nickel-based gamma/gamma prime chemistry on the tip of the aerofoil comprises depositing the layer of nickel-based gamma/gamma prime chemistry on the tip by electroplating.

8 . The method of claim 1 , wherein depositing the plurality of abrasive particles further comprises depositing the plurality of abrasive particles by electroplating.

9 . The method of claim 1 , wherein:
depositing the layer of nickel-based gamma/gamma prime chemistry on the tip of the aerofoil further comprises depositing the layer of nickel-based gamma/gamma prime chemistry by direct laser deposition; and depositing the plurality of abrasive particles on the layer of nickel-based gamma/gamma prime chemistry further comprises depositing the plurality of abrasive particles by direct laser deposition.

10 . The method of claim 1 , wherein each of the plurality of abrasive particles comprises cubic boron nitride.

11 . The method of claim 1 , further comprising providing a vacuum or an inert atmosphere around the tip during the heating of the tip at the predetermined temperature.

12 . The method of claim 1 , wherein the predetermined temperature is between 1200° C. and 1300° C.

13 . The method of claim 1 , wherein at least some of the abrasive particles are partially embedded within the layer of nickel-based gamma/gamma prime chemistry and partially extend from the layer of nickel-based gamma/gamma prime chemistry.

14 . An aerofoil for a gas turbine engine, the aerofoil comprising:
a body extending between a root and a tip; and a coating disposed on the tip, the coating comprising a layer of nickel-based gamma/gamma prime chemistry and a plurality of abrasive particles disposed on the layer of nickel-based gamma/gamma prime chemistry, the strength of the coating being increased by heating the tip of the aerofoil at a predetermined temperature in order to perform heat treatment of the coating matrix.

15 . The aerofoil of claim 14 , wherein the aerofoil is a turbine blade.

Assignees

• Rolls Royce Plc

Inventors

• Hewitt Andrew
• Hancock Matthew

Classifications

• F01D5/288 Primary

  Protective coatings for blades · CPC title

• C25D7/008

  Thermal barrier coatings · CPC title

• F05D2230/40

  Heat treatment · CPC title

• F05D2230/90

  Coating; Surface treatment · CPC title

• F05D2300/175

  Superalloys · CPC title