Components with cooling channels and manufacturing methods

The present invention relates generally to gas turbine engines, and more specifically to microchannel cooling therein.

In a gas turbine engine, air is compressed in a compressor and mixed with fuel in a combustor to generate hot combustion gas. From that gas energy in a high pressure turbine (HPT) that drives a compressor, in a fan drive in aircraft turbofan engine applications, or in a low pressure turbine (LPT) that drives an external shaft in shipping and industrial applications. Is extracted.

Engine efficiency increases with the temperature of the combustion gas. However, the combustion gas heats various components along its flow path, which requires cooling these components to achieve an acceptable long engine life. Usually, the components of the hot gas path are cooled by flowing air from the compressor. This cooling process reduces engine efficiency because the effluent is not used in the combustion process.

Gas turbine engine cooling technology is mature and includes numerous patents for various aspects of cooling circuits and features in various hot gas path components. For example, a combustor contains radial outer and inner liners, which require cooling during operation. The turbine nozzle contains a hollow vane that is supported between the outer and inner bands, which also requires cooling. Turbine rotor blades are hollow and typically include cooling circuits within them, which are surrounded by turbine shrouds that also require cooling. The hot combustion gas is also discharged through an exhaust port that is lined and can be properly cooled.

In all of these exemplary gas turbine engine components, thin walls of high-strength superalloy metal are commonly used to reduce the component weight and minimize the need for cooling. Various cooling circuits and features are tuned for these individual components in their respective corresponding environments within the engine. For example, a series of internal cooling passages or bending passages may be formed in the components of the hot gas path. The cooling fluid may be supplied from the plenum to these bent passages, and the cooling fluid may flow through the passages to cool the substrate and any accompanying coatings of the components of the hot gas path. However, this cooling measure usually results in relatively low heat transfer coefficient and non-uniform component temperature profile.

Microchannel cooling provides cooling as close as possible to the heated area, thereby reducing the temperature difference between the hot and cold sides of the major load-bearing substrate material for a given heat transfer coefficient. This has the potential to significantly reduce cooling requirements. For some applications, it is desirable to form a channel with a narrow opening (relative to the hydraulic diameter of the channel), which makes it easier for the coating to bridge the channel. For example, it has recently been proposed to machine microchannels using a abrasive liquid jet. However, in some cases, if the nozzle orifice of the liquid jet is less than about 10 mils (0.254 mm), abrasive particles will clog the nozzle, resulting in loss of dimensional tolerances, poor machining, or machine operability. It can be difficult to form a sufficiently narrow channel top (limited opening), as this can lead to loss of.

Therefore, it is desirable to form a channel with a small opening (relative to the hydraulic diameter of the channel) so that a bridging coating can be easily applied over the entire opening of the channel.

<p><patcit num="1"><text>U.S. Pat. No. 8147196</text></patcit></p>

One aspect of the present invention is in a manufacturing method comprising the step of forming one or more grooves in a component comprising a substrate having an outer surface. This substrate has at least one interior space. Each groove extends at least partially along the substrate and has a base and an upper end. In this manufacturing method, a step of applying a structural coating on at least a part of the base material and plastically deforming the structural coating near the upper end of each groove so that the gap across the upper end of the groove is reduced. Further includes the step of treating at least a portion of the surface of the structural coating.

Another aspect of the invention lies in a manufacturing method comprising the step of forming one or more grooves in a component comprising a substrate having an outer surface. The substrate has at least one interior space, each groove extending at least partially along the substrate and having a base and an upper end. The manufacturing method further comprises the step of applying a structural coating on the substrate and the step of treating the surface of the structural coating so as to provide a cut surface on the surface of the structural coating in the vicinity of the grooves.

Yet another aspect of the invention lies in a component that includes a substrate with an outer surface and an inner surface, the inner surface defining at least one interior space. The outer surface defines one or more grooves, each groove extending at least partially along the outer surface of the substrate and having a base and an upper end. This component further comprises a structural coating placed on at least a portion of the substrate, the surface of which structural coating is cut in the vicinity of each groove. One or more entry holes are formed through the base of each groove to connect the grooves to their respective interior spaces via fluid communication. This component further includes an additional coating placed on at least a portion of the structural coating, with one or more grooves (s), the structural coating and the additional coating together to cool the component. Define multiple channels.

These and other features, embodiments, and advantages of the present invention are better understood by reading the detailed description below with reference to the accompanying drawings, in which similar symbols represent similar parts throughout the drawings.

<figref num="1">It is a schematic diagram of a gas turbine system.</figref><figref num="2">FIG. 5 is a schematic cross-sectional view of an example aerofil structure with a reentrant-shaped cooling channel according to an aspect of the present invention.</figref><figref num="3">FIG. 6 is a perspective view showing three exemplary microchannels that partially extend along the surface of a substrate and carry a coolant to each film cooling hole.</figref><figref num="4">FIG. 5 is a schematic diagram showing an example tool finishing path for forming a groove and a tapered outflow region at the discharge end of the groove.</figref><figref num="5">It is the schematic which shows the cooling channel of the reentrant shape of an example before performing the surface treatment after machining.</figref><figref num="6">It is the schematic which shows the cooling channel of the reentrant shape of FIG. 5 after the surface treatment after machining which introduces an irregularity into the surface after treatment.</figref><figref num="7">Aperture size D before surface treatment after machining₁FIG. 5 is a cross-sectional view of an example reentrant-shaped cooling channel partially covered by a structural coating comprising.</figref><figref num="8">After surface treatment after machining, the opening size of the structural coating is D₂It is a cross-sectional view of the reentrant-shaped cooling channel of FIG.</figref><figref num="9">FIG. 8 is a cross-sectional view of a reentrant-shaped cooling channel of FIG. 8 in which an additional coating is placed on top of the structural coating, with the additional coating extending over a plastically deformed opening of the structural coating.</figref><figref num="10">Aperture size D before surface treatment after machining₁FIG. 6 is a cross-sectional view of another exemplary cooling channel partially covered by a structural coating having.</figref><figref num="11">After surface treatment after machining, the opening size of the structural coating is D₂It is sectional drawing of the cooling channel of FIG.</figref><figref num="12">FIG. 10 is a cross-sectional view of a cooling channel of FIG. 10 in which an additional coating is placed on top of the structural coating, with the additional coating extending over a plastically deformed opening of the structural coating.</figref><figref num="13">FIG. 5 shows a reentrant-shaped channel with a permeable notch formed within a structural coating.</figref>

Terms such as "first" and "second" herein do not mean any order, quantity, or significance, but rather are used to distinguish one element from the other. The term "one" ("a" and "an") herein does not mean a quantity limitation, but means that there is at least one thing mentioned. The modifier "about" used in connection with a quantity includes the stated value and has a meaning dictated by the context (eg, including the degree of error associated with the measurement of a particular quantity). In addition, the term "combination" includes formulations, blends, alloys, reaction products and the like.

In addition, as used herein, "(s) (suffix" (s) ") usually includes both the singular and plural of the term it modifies, and thus one or more of that term. Intended to include more than one (eg, "passing hole" can include one or more through holes unless otherwise specified). References throughout the specification to "one embodiment," "another embodiment," "some embodiment," etc., are specific elements (eg, features, structures, and / or) that are described in connection with that embodiment. (Characteristics) is included in at least one embodiment described herein, meaning that it may or may not be present in the other embodiments. Similarly, the reference to "specific configuration" includes certain elements (eg, features, structures, and / or characteristics) mentioned in connection with that configuration within at least one configuration described herein, and others. It means that it may or may not be in the composition of. Moreover, it should be understood that the described inventive features may be combined in any suitable manner in various embodiments and configurations.

FIG. 1 is a schematic view of the gas turbine system 10. The system 10 may include one or more compressors 12, a combustor 14, a turbine 16, and a fuel nozzle 20. The compressor 12 and the turbine 16 may be connected by one or more shafts 18.

The gas turbine system 10 may include components 100 of several hot gas paths. A component of the hot gas path is any component of system 10 that is at least partially exposed to the flow of hot gas through system 10. For example, bucket assemblies (also known as blades or blade assemblies), nozzle assemblies (also known as vanes or vane assemblies), shroud assemblies, transition pieces, retention rings, and turbine exhaust components are all components of the hot gas path. Is. However, it should be understood that the component 100 of the hot gas pathway of the present invention is not limited to the above examples and may be any component that is at least partially exposed to the flow of high temperature gas. Further, it is understood that the component 100 of the hot gas path of the present disclosure is not limited to the component of the gas turbine system 10 and may be any mechanical device or component thereof exposed to high temperature flow. I want to be.

When the hot gas path component 100 is exposed to the hot gas flow, the hot gas path component 100 is heated by the hot gas flow to a temperature at which the hot gas path component 100 significantly deteriorates or fails. May reach. Therefore, in order to allow the system 10 to operate with the hot gas stream at the high temperature required to achieve the desired efficiency, performance and / or life of the system 10, the components 100 of the hot gas path. A cooling system is needed for this.

Generally, the cooling system of the present disclosure includes a series of small channels or microchannels formed on the surface of component 100 of a hot gas path. For industrial scale powered turbine components, the dimensions of the "small" or "micro" channels are considered to include an approximate depth and width in the range of 0.25 mm to 1.5 mm, while aircraft industry scale turbines. The component channel dimensions will include an approximate depth and width in the range 0.1 mm to 0.5 mm. The components of the hot gas path may be coated with a protective coating. The cooling fluid may be supplied from the plenum to the channel, and the cooling fluid may flow through the channel to cool the components of the hot gas path.

The manufacturing method is described with reference to FIGS. 2-12. For example, as shown in FIGS. 2 and 3, the manufacturing process involves one or more grooves 132 in component 100 including a substrate 110 with an outer surface 112, which partially defines channel 130 in FIG. Includes the step of forming). As shown in FIG. 2, the substrate 110 has at least one interior space 114. For example, as shown in FIG. 3, each groove 132 extends at least partially along the substrate 110 and has a base 134 and an upper end 146. As discussed below, the entry hole 140 connects the grooves to their respective interior spaces. Note that the holes 140 shown in FIG. 3 are individual holes arranged in the cross section shown and do not extend through the substrate along the length of the groove 132.

The substrate 110 is usually cast before forming the (s) grooves 132. US Pat. No. 5,626,462, "Double-wall" by Melvin R. Jackson et al., Which is incorporated herein by reference in its entirety. As discussed in "airfoil", the substrate 110 may be formed from any suitable material. Depending on the intended use for component 100, this may be Ni principal component, Co principal component, and Fe principal component. Can contain component superalloys. Ni-based superalloys contain both γ and γ'phases, especially those in which the γ'phase accounts for at least 40% of the volume of the superalloy. It may contain both. Such alloys are known to be advantageous due to the combination of desirable properties, including high temperature strength and high temperature creep resistance. The substrate material is also between the metals of NiAl. It may contain alloys, for which it is known that these alloys also have a combination of excellent properties, including high temperature strength and high temperature creep resistance, which are convenient for use in turbine engine applications used in aircraft. In the case of the Nb main component alloy, a coated Nb main component alloy having excellent antioxidant properties is preferable, and in particular, Nb- (27 to 40) Ti- (4.5 to 10.5) Al- Alloys containing (4.5 to 7.9) Cr- (1.5 to 5.5) Hf- (0 to 6) V are preferred, where the unit of composition range is atomic percent. The substrate material is silicate, charcoal, or boride. It may also contain Nb principal component alloys containing at least one secondary phase, such as Nb-containing metallized compounds containing ) Is a composite material. As another composition, the base material is Mo.₅SiB₂And / or Mo₃Contains molybdenum-based alloys such as molybdenum-based alloys (solid solutions) with the second phase of Si. In other configurations, the substrate material comprises a ceramic matrix composite (CMC) such as a SiC matrix reinforced with silicon carbide (SiC) fibers. In another configuration, the substrate material contains an intermetallic compound that is the main component of TiAl.

The groove 132 may be of any of several different shapes. In the exemplary configuration shown in FIGS. 5-9, each groove 132 is narrowed at its respective upper end 146, whereby each groove 132 has a reentrant shaped groove 132. Reentrant-shaped grooves are discussed in R. Bunker et al., US Patent Application Publication No. 12 / 943,624, "Components with re-entrant shaped cooling channels and methods of manufacture," which were assigned to the assignee of the invention. , Which is incorporated herein by reference in its entirety. In the exemplary configuration shown in FIGS. 10-12, the groove 132 is square in cross section. The groove is shown to have a straight wall, but the groove 132 may have any wall structure, eg, straight or curved.

The groove 132 can be formed using a variety of techniques. Illustrative techniques for forming (s) grooves 132 include abrasive liquid jets, plunge electrochemical machining (ECM), electrical discharge machining (EDM), electrical discharge machining with rotating electrodes (milling EDM), And laser machining included. An exemplary laser machining technique is described in US Patent Application Publication No. 12 / 697,005, Process and system for forming shaped air holes, filed January 29, 2010, assigned to the assignee of the invention. This is incorporated herein by reference in its entirety. An exemplary EDM technique is described in US Patent Application Publication No. 12 / 790,675, Articles which include chevron film cooling holes, and related processes, filed May 28, 2010, assigned to the assignee of the invention. It has been incorporated herein by reference in its entirety.

In certain treatments, grooves are formed using an abrasive liquid jet 160 (Figure 4). The exemplary abrasive liquid jet grinding process and system was assigned to the assignee of the invention, US Patent Application Publication No. 12 / 790,675, filed May 28, 2010, Articles which include chevron film cooling holes. , and related Provided in "processes", which are incorporated herein by reference in their entirety. As described in US Patent Application Publication No. 12 / 790,675, abrasive liquid jet treatments are typically in high pressure water streams. Utilize a high-speed flow of abrasive particles suspended in (eg, abrasive "grids"). The pressure of the liquid can vary significantly, but is often in the range of about 35-620 MPa. Several abrasive materials such as garnet, aluminum oxide, silicon carbide, and glass beads can be used. Advantageously, the ability of abrasive liquid jet processing technology facilitates the removal of material at various depth stages while controlling the shape of the features being processed. It can grind the internal entry hole 140 that supplies the channel as either a straight hole with a constant cross section, a molded (eg oval) hole, or a focusing or spreading hole (not shown). To.

In addition, the waterjet system may include a multi-axis computer numerical control (CNC) unit 210 (Figure 4), as described in US Patent Application Publication No. 12 / 790,675. The CNC system itself is known in the art and is described, for example, in US Patent Application Publication No. 1005/0013926 (S. Rutkowski et al.), Which is incorporated herein by reference in its entirety. The CNC system allows the cutting tool to move along some of the X, Y, and Z axes, as well as the tilt axis.

With reference to FIG. 7, the manufacturing method further includes the step of applying the structural coating layer 54 on at least a part of the base material 110. The structural coating layer 54 can be deposited using a variety of techniques. In certain treatments, the structural coating may be deposited by performing ion plasma deposition (also known in the art as cathode arc deposition). Examples of devices and methods for ion plasma deposition are described in US Patent Application Publication No. 1008/0138529 by Weaver et al., Method and apparatus for cathodic arc ion plasma, which was assigned to the assignee of the present invention. Provided in "deposition", which is incorporated herein by reference in its entirety. Briefly, ion plasma deposition vacuum chambers a consumable cathode with a composition to produce the desired coating material. The process of arranging inside, the process of supplying the base material 110 into a vacuum environment, the process of supplying current to the cathode to form a cathode arc on the cathode surface, and as a result the arc-induced coating material from the cathode surface. It includes a step of causing erosion and a step of depositing a coating material from the cathode on the substrate surface 112.

A non-limiting example of a structural coating deposited using ion plasma deposition is described in Jackson et al., US Pat. No. 5,626,462, "Double-wall airfoil". In a high temperature gas path component 100, the structural coating 54 comprises a nickel-based or cobalt-based alloy, more specifically a superalloy or a (Ni, Co) CrAlY alloy. If the substrate material is a Ni-based superalloy containing both γ and γ'phases, the structural coating may contain a material composition similar to that discussed in US Pat. No. 5,626,462. Furthermore, as a superalloy, the structural coating 54 is γ'-Ni.₃It may contain a composition containing an Al-based alloy as a main component.

More generally, it is believed that the composition of the structural coating is determined by the composition of the underlying substrate. For example, in a CMC substrate such as a SiC matrix reinforced with silicon carbide (SiC) fibers, the structural coating is typically considered to contain silicon.

In other treatment configurations, the structural coating 54 is deposited by performing at least one of a thermal spraying treatment and a cold spraying treatment. For example, thermal spraying may include combustion spraying or plasma spraying, combustion spraying may include high speed oxygen fuel spraying (HVOF) or high speed air fuel spraying (HVAF), and plasma spraying may include atmospheric pressure (air or inert gas). Etc.) may include plasma spraying or reduced pressure plasma spraying (also known as LPPS, vacuum plasma spraying or VPS). In one non-limiting example, the (Ni, Co) CrAlY coating is deposited by HVOF or HYAF. Other exemplary techniques for depositing structural coatings include, but are not limited to, sputtering, electron beam physical vapor deposition, entrapment plating, and electroplating.

In the exemplary process depicted in FIGS. 5-12, the manufacturing process involves the surface 55 of the structural coating 54 to plastically deform the structural coating 54 at least in the vicinity of the upper end 146 of each groove 132. Further includes the step of processing at least a part of the above. The resulting treated structural coating 54 is shown, for example, in FIGS. 8 and 11, and the gap across the top 146 of the groove 132 is treated, as shown, for example, in FIGS. 7, 8, 10 and 11. As a result, it is made smaller. In addition to the structural coating, the underlying substrate 110 may also be plastically deformed to some extent. Thus, the process of treating the surface 55 affects the sustained deformation of both the coating material or the underlying material of the coating and its underlying layer. Advantageously, by reducing the gap across the top of the groove, the process allows the coating to open the opening directly (ie, sacrificing filling, as shown, for example, FIGS. 9 and 12). Improve the ability to bridge (without using). In addition, by reducing the clearance across the upper end of the groove, the manufacturing process facilitates the use of more lenient machining specifications across the upper end of the groove. Advantageously, by lowering this processing specification, the manufacturing method can reduce the processing cost for the channel. In addition, plastic deformation of the coating can reduce or prevent local plastic deformation of the substrate, which can lead to unintentional recrystallization of the structural superalloy substrate.

In addition, the process may further optionally include the step of preheating the substrate during or prior to the deposition of the structural coating. In addition, the manufacturing process may further include a step of heat-treating the components (eg, vacuum heat-treating at 1100 ° C. for 2 hours) after the structural coating has deposited and before treating the surface of the structural coating. It may be included. Therefore, the step of treating the surface of the structural coating can be pre-heating or post-heating. These heat treatment options can improve the adhesion of the coating to the substrate and / or increase the ductility of the coating, both of which plastically deform the coating and the top edge of the groove. Facilitates the treatment of the substrate after coating to reduce the gap across the section. In addition, the manufacturing process may further include, optionally, a step of performing one or more grit blasting operations. For example, it is possible that the surface 112 of the substrate may be grit blasted prior to applying the structural coating 54. In addition, it may optionally undergo surface grit blasting after treatment, thereby improving the adhesion of the coating that deposits later. The grit blasting operation is usually performed after the heat treatment, not just before the heat treatment.

U.S. Patent Application Publication No. 13 / 242,179, assigned to the assignee of the invention, applies a similar treatment to the substrate. However, by treating the structural coating (s), the method described above is advantageous in that the structural coating can be more ductile than the substrate and therefore more adaptable to plastic deformation. Is. In addition, the defects induced in the structural coating by the deformation process will affect the lower debit of the components after coating, and during the subsequent heat treatment of the substrate It can be repaired more easily than a defect. Systems with structural coatings can therefore be transformed to a higher degree than possible with uncoated substrates using the methods of US Patent Application Publication No. 13 / 242,179 using the methods described above. In addition, if the deformation is limited to structural coatings, the system can also avoid recrystallization of the substrate (in connection with the method of US Patent Application Publication No. 13 / 242,179). It leads to improved mechanical properties under periodic loading.

Although not specifically shown, in certain applications, the treatment of the surface 55 of the structural coating 54 reduces the gap in the structural coating 54 near the upper end 146 of the groove 132. As used herein, "reducing the gap" means that the width of the gap after processing is smaller than that before processing. In certain configurations, this process closes the opening geometrically, and "geometrically closing" means that the structural coating 54 is brought into close proximity to the coating from the opposite side of the groove opening, effectively Means to close the gap. Therefore, as used herein, geometric closure is not equivalent to metallurgical adhesion. However, in some processing configurations, metallurgical adhesions may actually be formed. Advantageously, reducing the size of the gap further enhances the ability of the coating to bridge directly to the opening.

Referring now to FIGS. 5-12, the surface 55 of the structural coating 54 plastically deforms the structural coating 54 (and possibly a portion of the substrate 110) at least in the vicinity of the groove 132, thereby thereby. Shot peening of surface 55, water jet peening of surface 55, flap peening of surface 55, gravity peening of surface 55, ultrasonic waves of surface 55 to reduce the gap across the upper end 146 of the groove 132. It may be processed using one or more of a variety of techniques including formula peening, surface 55 vanishing, surface 55 low plastic peening, and surface 55 laser shock peening.

In certain treatments, the surface 55 of the structural coating 54 is treated by shot peening. For example, as shown in FIG. 6, shot peening usually introduces some surface irregularities into the surface 55 of the structural coating 54. Advantageously, this surface irregularity helps bridge coatings that deposit on the surface, especially those that are deposited using treatments such as ion plasma deposition, electron beam physical vapor deposition, and sputtering.

In other treatments, the surface 55 of the structural coating 54 is treated with a vanish finish. A variety of vanishing techniques can be used, depending on the material being surface-treated and the desired deformation. Non-limiting examples of vanishing techniques include, for example, the process of plastically rubbing the surface of a structural coating using rollers, pins, or balls, and low plastic vanishing.

The gap across the top of the groove varies based on the particular application. However, in some configurations, the gap across the upper end 146 of the groove 132 is in the range of about 8 to 31 mils (0.2 to 0.8 mm) before the treatment of the surface 55 of the structural coating 54, of the structural coating 54. After the surface 55 treatment, the gap across the upper end 146 of the groove 132 is in the range of about 0-15 mils (0-0.4 mm).

In certain configurations, the step of treating the surface 55 of the structural coating 54 also adds a cut surface to the structural coating 54 in the vicinity of the groove 132. As used herein, "adding a cut surface" is understood to tilt the surface 55 towards the groove in the vicinity of the groove 132, as shown, for example, in the circled area of FIG. Should be.

For example, as shown in FIGS. 9 and 12, the manufacturing method further comprises placing an additional coating 150 on at least a portion of the surface 55 of the structural coating 54. Note that this additional coating 150 may include one or more different coating layers. For example, the coating 150 may include additional coating layers (s) that are optionally applied, such as additional structural and / or adhesive coatings, thermal barrier coatings (TBCs) and antioxidant coatings. In certain configurations, the additional coating 150 may include an outer structural coating layer (also indicated by reference numeral 150). For example, as shown in FIGS. 9 and 12, the groove 132 (s), the structural coating 54 and the additional coating 150 define one or more channels 130 for cooling the component 100. ..

In certain configurations, the structural coating 54 and the additional coating 150 range from 0.1 to 2.0 mm for industrial components, more specifically from 0.2 to 1 mm, and even more specifically from 0.2 to 0.5 mm. Has the thickness after the combination of. For aircraft components, this range is typically 0.1-0.25 mm. However, other thicknesses may be utilized depending on the requirements for the particular component 100.

The coating layer (s) can be deposited using a variety of techniques. An exemplary deposition technique for forming a structural coating is provided above. In addition to structural coatings, adhesive coatings, TBC and antioxidant coatings can also be deposited using the techniques described above.

In some configurations, it is desirable to use multiple deposition techniques to deposit the structural coating layer and optionally additional coating layers. For example, the first structural coating layer may be deposited using ion plasma deposition, the subsequent deposition layer and optionally additional layers (not shown) may be combustion sprayed or plasma sprayed, etc. It may be deposited using other techniques. The use of different deposition techniques for the coating layer, depending on the material used, can provide benefits in properties such as strain tolerance, strength, adhesiveness, and / or ductility, without limitation.

In addition to the step of treating the surface 55 of the structural coating 54, in some treatment configurations, the manufacturing method may groove at least a portion of the surface 155 (FIGS. 9, 12 and 13) of the additional coating 150, respectively. In some cases, an additional step of processing the additional coating 150 to plastically deform it may be included, at least in the vicinity of the upper end 146 of 132. For example, the additional coating may include another layer of structural or adhesive coating. Advantageously, additional treatment can reduce the width of the gap across the top 146 of the groove, so that any subsequent coating layer deposits more easily directly (ie, sacrifices) the opening. It is possible to bridge (with or without a breathable gap, as discussed below with reference to FIG. 13) (without the use of such fillers).

In addition, in some treatment configurations, the process may optionally include treating at least a portion of the outer surface 112 of the substrate 110 in order to plastically deform each portion of the substrate 110. .. (See, eg, Figure 8 of US Patent Application Publication No. 13 / 242,179.) This additional, optionally performed step may be performed prior to the step of applying the structural coating 54 on the substrate 110. Good. Advantageously, this additional processing step can reduce the width of the opening 146 as described in US Patent Application Publication No. 13 / 242,179.

Embodiments of another manufacturing method of the present invention are described with reference to FIGS. 2 and 3 and FIGS. 5-12. For example, as shown in FIG. 2, the manufacturing method comprises forming one or more grooves 132 in a component 100 including a substrate 110 having an outer surface 112. As shown in FIG. 2, the substrate 110 has at least one interior space 114. For example, as shown in FIG. 3, each groove 132 extends at least partially along the substrate 110 and has a base 134 and an upper end 146.

As mentioned above, the substrate 110 is usually cast before forming the (s) grooves 132. Techniques for forming grooves 132 have been described above and include, but are not limited to, abrasive liquid jets, plunge electrochemical machining (ECM), electrical discharge machining (EDM), electrical discharge machining with rotating electrodes (milling EDM), And include the step of using one or more of laser machining. Groove 132 is also mentioned above. As discussed above, the groove 132 may have any of several shapes. For example, in the configuration shown in FIGS. 5-9, each groove 132 is narrowed at its respective upper end 146 so that each groove 132 is a reentrant shaped groove 132.

Referring here to FIG. 7, the manufacturing method further comprises the step of applying a structural coating 54 on the substrate 110. An exemplary deposition technique and an exemplary suitable material for this structural coating 54 are described above.

In the exemplary treatments depicted in FIGS. 5-12, the manufacturing process further processes the surface 55 of the structural coating 54 in the vicinity of the groove 132 to provide a cut surface to the surface 55 of the structural coating 54. Including. As mentioned above, "adding a cut surface" should be understood as tilting the surface 55 towards the groove near the groove 132, for example, as shown in the circled area of FIG. .. Advantageously, tilting the surface 55 towards the groove in the vicinity of the groove improves the bridging over the groove opening of the coating 150 that subsequently deposits (without the use of sacrificial fillings). Relaxes the mechanical specifications for groove openings and facilitates the use of larger water jet nozzles to form grooves. This reduces the time required to form the groove, as well as the associated processing costs.

As mentioned above, some techniques can be used to treat the surface 55 of the structural coating 54, at least in the groove so that the gap across the top 146 of the groove 132 is small. Shot peening of surface 55, water jet peening of surface 55, flap peening of surface 55, gravity peening of surface 55, surface 55 to make a cut surface on the surface 55 of the structural coating 54 adjacent to one edge 135. Includes the steps of performing one or more of ultrasonic peening, surface 55 vanishing, surface 55 low plastic peening, and surface 55 laser shock peening.

In certain treatment configurations, the surface 55 of the structural coating 54 is treated by shot peening of the surface 55. For example, as shown in FIG. 6, shot peening introduces some surface irregularities into the surface 55 of the structural coating 54. As mentioned above, this surface irregularity is examined for coatings deposited on this surface, especially those deposited using ion plasma deposition, electron beam physical vapor deposition, and sputtering (see Figure 13 below). It is possible to help bridging (with a complete or breathable gap 144) without the use of sacrificial fillings.

With reference to FIGS. 9 and 12, the manufacturing process may optionally further include placing an additional coating 150 on at least a portion of the surface 55 of the structural coating 54. As mentioned above, this additional coating 150 may be one or more different coatings. For example, as shown in FIG. 9, the groove 132 (s), the structural coating 54 and the additional coating 150 define one or more channels 130 for cooling the component 100. The additional coating 150 contains the appropriate material and is adhered to the component. Exemplary materials and deposition techniques for additional coatings are described above.

In addition to the step of treating the surface 55 of the structural coating 54, in some treatment configurations, the manufacturing method of the additional coating 150 to make a cut surface on the surface 155 near the top 146 of each groove 132. It may further include the step of treating at least a portion of the surface 155 (FIGS. 9, 12, and 13). For example, the additional coating may include a structural coating or an adhesive coating or an outer layer of TBC. As mentioned above, the additional treatment can conveniently reduce the gap across the top 146 of the groove, which makes it easier for any subsequent coating layer to open. It is possible to bridge directly (ie, without the use of sacrificial filling) (completely or with a breathable gap 144).

In addition, in some treatment configurations, the process may optionally include the step of treating at least a portion of the outer surface 112 of the substrate 110 in order to plastically deform each portion of the substrate 110. (See, eg, Figure 8 of US Patent Application Publication No. 13 / 242,179.) This optional additional processing step may be performed prior to the step of applying the structural coating 54 on the substrate 110. Good. As mentioned above, this additional processing step can reduce the width of the opening 146 as described in US Patent Application Publication No. 13 / 242,179.

Embodiments of component 100 of the present invention are described with reference to FIGS. 2, 3, 6-9, 12, and 13. For example, as shown in FIG. 2, component 100 includes a substrate 110 having an outer surface 112 and an inner surface 116. For example, as shown in FIG. 2, the inner surface 116 defines at least one interior space 114. As shown in FIG. 3, the outer surface 112 defines one or more grooves 132. Each groove 132 extends at least partially along the outer surface 112 of the substrate 110 and has a base 134 and an upper end (opening) 146. In the configuration shown in FIG. 3, each groove 132 is narrowed at its respective upper end 146 so that each groove 132 is a reentrant shaped groove 132. However, these grooves may have yet other shapes. Groove 132 is described in detail above.

For example, as shown in FIG. 7, the component 100 further comprises a structural coating 54 disposed on at least a portion of the substrate 110. For example, as shown in FIG. 8, the surface 55 of the structural coating 54 is cut in the vicinity of each groove 132.

For example, as shown in FIGS. 3 and 13, one or more entry holes 140 penetrate the base 134 of each groove 132 to connect the grooves 132 to their respective interior spaces 114 (FIG. 13) in fluid communication. Is formed. Note that the entry hole 140 is a separate hole and is therefore not co-extended with channel 130, for example as shown in FIG.

With reference to FIGS. 9, 12 and 13, component 100 further includes an additional coating 150 placed on at least a portion of the structural coating 54. As mentioned above, the additional coating may include one or more coating layers having a single or different composition. For example, as shown in FIG. 9, the groove 132 (s), the structural coating 54 and the additional coating 150 together define one or more channels 130 for cooling the component 100.

In the particular configuration depicted in FIG. 6, some surface irregularities are formed on the surface 55 of the structural coating 54 in the vicinity of each groove 132.

As discussed above, in certain configurations, the additional coating 150 may include an outer structural coating layer, which is also indicated by reference numeral 150. Although not specifically shown, in certain configurations, the surface 155 of the additional coating 150 may also be cut in the vicinity of each groove 132. Further, although not specifically shown, in a specific configuration, the base material 110 itself may be plastically deformed in the vicinity of each groove 132.

Advantageously, the manufacturing method described above can affect the complete or partial closure of the gaps in the channel surface by treating the surface of the structural coating to plastically deform. This, in turn, facilitates channel bridging with the next coating, including the possibility of breathable gap 144 discussed above with reference to FIG. The resulting final component is therefore expected to show no evidence of microchannels, visible crevices, or gaps. This provides a more uniform structural coating in terms of microstructure and strength when applied on top of the treated structural coating.

Although only certain features of the invention have been exemplified and described herein, those skilled in the art will appreciate many modifications and modifications. Therefore, it should be understood that the appended claims are intended to cover such modifications and modifications as being within the true spirit of the invention.

10 Gas Turbine System 12 Compressor 14 Combustor 16 Turbine 18 Shaft 20 Fuel Nozzle 54 Structural Coating 55 Outer Surface of Structural Coating 56 (One or More) Additional Coating (Outer Structural Coating) 100 Hot Gas Path Components 110 Base Material 112 Base Material Outer Surface 114 Internal Space 116 Base Material Inner Surface 130 Cooling Channel 132 (One or More) Grooves 135 Groove Edge 134 Groove Base 140 (One or More) Ingress Hole 144 (One or more) Breathable Gap 146 Top of Groove 150 Additional Coating 155 Surface of Additional Coating 160 Polishable Liquid Jet 170 Discharge End 172 (One or More) Film Cooling Hole 210 Multi-axis computer numerical control (CNC) unit