Methods for manufacturing an additively manufactured fuel contacting component to facilitate reducing coke formation

Patent metadata

Field	Value
Publication number	US-9334806-B2
Application number	US-201314018537-A
Country	US
Kind code	B2
Filing date	Sep 5, 2013
Priority date	Sep 5, 2013
Publication date	May 10, 2016
Grant date	May 10, 2016

Abstract

A method for manufacturing a fuel contacting component that facilitates reducing coke formation on at least one surface of the fuel contacting component is disclosed herein. The method includes applying a slurry composition including a powder including aluminum to the component surface, wherein the fuel contacting component is formed by an additive manufacturing process. The slurry composition is heat treated to diffuse the aluminum into the component surface. The heat treatment comprises forming a diffusion aluminide coating on the component surface, wherein the diffusion coating comprises a diffusion sublayer formed on the component surface and an additive sublayer formed on the diffusion sublayer. The method further comprises removing the additive sublayer of the diffusion aluminide coating with at least one aqueous solution such that the diffusion sublayer and the component surface are substantially unaffected, wherein the diffusion layer facilitates preventing coke formation on component surface.

First claim

What is claimed is:

1. A method of manufacturing a fuel contacting component that facilitates reducing coke formation on at least one surface of the fuel contacting component exposed to a liquid fuel, said method comprising:
applying a slurry composition that includes a powder including aluminum to the at least one surface, wherein the fuel contacting component is formed by an additive manufacturing process;
heat treating the slurry composition to diffuse the aluminum into the at least one surface, wherein heat treating comprises forming a diffusion aluminide coating including a diffusion sublayer on the at least one surface and an additive sublayer on the diffusion sublayer; and
removing the additive sublayer of the diffusion aluminide coating with at least one aqueous solution such that the diffusion sublayer and the at least one surface are substantially unaffected, wherein the diffusion sublayer facilitates preventing coke formation on the at least one surface, wherein the diffusion aluminide coating has a thickness of between about 10 to about 125 μm, the diffusion sublayer has a thickness in a range between 0.5 μm and 50 μm, and the additive sublayer has a thickness in a range between 25 μm and 150 μm.

2. The method of claim 1 , further comprising:
forming a coating residue on the at least one surface after treatment in the aqueous solution; and
removing the coating residue using a technique including at least one of abrasion, tumbling, laser ablation, and ultrasonic agitation.

3. The method of claim 1 , wherein the at least one surface is a surface of a fuel nozzle for use in a gas turbine engine.

4. The method of claim 1 , wherein the at least one surface is formed from one of a nickel-based or cobalt-based superalloy.

5. The method of claim 1 , wherein the diffusion aluminide coating has a thickness within a range between approximately 10 micrometers and approximately 125 micrometers.

6. The method of claim 1 , wherein the at least one aqueous solution is selected from the group including at least one of hydroflourozirconic acid, hydrofluorosilicic acid, hydrochloric acid, or a combination thereof.

7. The method of claim 1 , wherein applying a slurry composition further comprises at least one of spraying the slurry composition onto the at least one surface, immersing the fuel contacting component in a bath of the slurry composition, and vapor phase aluminizing.

8. The method of claim 1 , further comprising depositing at least one noble metal on the at least one surface.

9. The method of claim 1 , wherein the at least one aqueous solution is present in a treatment composition at a molarity level in the range of about 0.5 M to about 5 M.

10. The method of claim 1 , further comprising immersing the fuel contacting component having the diffusion aluminide coating in a bath of the at least one aqueous solution for a time period in a range between approximately 10 minutes and approximately 4 hours.

11. The method of claim 10 , further comprising maintaining the at least one aqueous solution at a temperature in a range between approximately 30° C. and approximately 85° C.

12. The method of claim 1 , further comprising applying the heat treatment for a time period in a range between approximately 1 hour and approximately 4 hours.

13. The method of claim 12 , further comprising applying the heat treatment at a temperature in the range of between approximately 1200° F. and approximately 1600° F.

14. The method of claim 13 , wherein applying the heat treatment comprises maintaining a temperature of approximately 1200° F. for approximately 10 minutes, then increasing the temperature to about 1600° F. in increments of approximately 45° F./minute, and maintaining a temperature of approximately 1600° F. in a range of between about one to about four hours.

15. The method of claim 1 , wherein the powder including aluminum comprises between about 40 weight percent and about 70 weight percent of the slurry composition.

16. The method of claim 15 , wherein the aluminum has an average particle size in a range between about 0.5 micrometers and about 100 micrometers.

17. The method of claim 15 , wherein the slurry composition includes at least one binder selected from the group including at least one of colloidal silica, an organic resin, and a combination thereof.

18. The method of claim 17 , wherein the slurry composition includes an organic stabilizer selected from the group including an alkane diol, glycerol, pentaerythritol, a fat, a carbohydrate, and a combination thereof.

19. The method of claim 18 , wherein colloidal silica comprises between about 20 weight percent and about 40 weight percent of the slurry composition and organic stabilizer comprises about 5 weight percent to about 15 weight percent of the slurry composition.

Assignees

• Gen Electric

Inventors

• Carter William Thomas
• Ruud Jr James Anthony
• Kool Lawrence Bernard
• Gambone Jr Justin John
• Furstoss Christine Mary

Classifications

• F02C7/30 Primary

  Preventing corrosion {or unwanted deposits} in gas-swept spaces · CPC title

• B22F3/22 Primary

  for producing castings from a slip · CPC title

• B22F10/80

  Data acquisition or data processing · CPC title

• B22F12/50

  Means for feeding of material, e.g. heads · CPC title

• B22F10/66

  by mechanical means · CPC title