|
(11) | EP 4 455 361 A2 |
| (12) | EUROPEAN PATENT APPLICATION |
|
|
|
|
|||||||||||||||||||||||||||
| (54) | ELECTROLESS DEPOSITED COATING WITH STIFFENERS |
| (57) A method for manufacturing an engine component (20) comprises providing a preform
engine component (26) that includes a substrate (22) having a substrate surface (28)
and a plurality of apertures (30). Each of the apertures (30) projects partially into
the substrate (22) from the substrate surface (28). A coating (24) is formed on the
substrate (22) and includes a base (40) and a plurality of projections (42). The base
(40) covers the substrate surface (28). Each of the projections (42) projects out
from the base (40) into and fills a respective one of the apertures (30). The forming
of the coating (24) includes electroless plating a coating material (68) onto the
substrate (22) over the substrate surface (28) and within the apertures (30).
|
TECHNICAL FIELD
[0001] This disclosure relates generally to a coating process and, more particularly, to coating a substrate of an aircraft engine component.
BACKGROUND INFORMATION
[0002] Various components of an aircraft engine, such as a gas turbine engine, include coatings. Various types of coatings are known in the art and various methods for applying those coatings are known in the art. While these known coatings and application methods have various benefits, there is still room in the art for improvement.
SUMMARY
[0003] According to an aspect of the invention, a method is provided for manufacturing an engine component. During this method, a preform engine component is provided that includes a substrate. The substrate includes a substrate surface and a plurality of apertures. Each of the apertures projects partially into the substrate from the substrate surface. A coating is formed on the substrate. The coating includes a base and a plurality of projections. The base covers the substrate surface. Each of the projections projects out from the base into and fills a respective one of the apertures. The forming of the coating includes electroless plating a coating material onto the substrate over the substrate surface and within the apertures.
[0004] According to another aspect of the invention, a method is provided for manufacturing an aircraft engine component. During this method, a substrate is provided that includes an electrically non-conductive material. The substrate includes a substrate surface and a plurality of apertures. Each of the apertures projects partially vertically into the substrate from the substrate surface. A coating material is electroless plated onto the substrate to form a plated structure. The plated structure includes a base and a plurality of projections. The base covers the substrate surface. Each of the projections projects vertically out from the base into and fills a respective one of the apertures. The aircraft engine component includes the plated structure.
[0005] According to still another aspect of the invention, another method is provided for manufacturing an engine component. During this method, a substrate is provided that includes a substrate surface and a plurality of apertures. Each of the apertures projects partially vertically into the substrate from the substrate surface. A coating material is electroless plated onto the substrate to form the engine component. The engine component includes a base and a plurality of projections. The base covers the substrate surface. Each of the projections projects vertically out from the base into and fills a respective one of the apertures. The substrate is removed from the engine component.
[0006] The present invention, and any of the above aspects of the invention, may include any one or more of the individual features disclosed above and/or below alone or in any combination thereof.
[0007] The aircraft engine component may also include the substrate. The substrate may form a preform of the aircraft engine component.
[0009] The electroless plating may include disposing the substrate into a bath of ions of the coating material in an aqueous solution. The coating material may be plated onto the substrate through an autocatalytic chemical reduction of the ions of the coating material.
[0013] The coating may be the coating material. The coating, for example, may only include the coating material.
[0014] The coating may include a base layer and an outer layer. The base layer may be between the substrate and the outer layer. The coating material may be electroless plated onto the substrate to form the base layer. The outer layer may be or otherwise include a second coating material.
[0017] The coating may include a base layer and an outer layer. The coating material may be electroless plated onto the substrate to form the base layer. The forming of the coating may also include electroplating a second coating material onto the base layer to form the outer layer.
[0018] The base may have a vertical thickness. The projections may include a first projection. The first projection may have a vertical height that is equal to or greater than one-half of the vertical thickness.
[0019] The projections may include a first projection. The first projection may include a web and an anchor. The web may project vertically out from the base to the anchor. A lateral width of the anchor may be greater than a lateral width of the web.
[0020] The apertures may include a first aperture. The projections may include a first projection. The first projection may project vertically out from the base into the first aperture. A portion of the substrate may be disposed vertically between the base and a portion of the first projection.
[0021] A second portion of the substrate may be disposed vertically between the portion of the first projection and a second portion of the first projection.
[0022] A first of the apertures may extend longitudinally along a first centerline within the substrate. A second of the apertures may extend longitudinally along a second centerline within the substrate. At least a portion of the second centerline may be non-parallel with the first centerline.
[0023] A first of the apertures may extend longitudinally along a first centerline within the substrate. A second of the apertures may extend longitudinally along a second centerline within the substrate. At least a portion of the second centerline may be parallel with the first centerline.
[0024] A first of the apertures may extend longitudinally along a first centerline within the substrate. At least a portion of the first centerline may be non-straight.
[0025] A first of the apertures may extend longitudinally along a first centerline within the substrate. At least a portion of the first centerline may be straight.
[0026] The engine component may be an aircraft engine component that includes the substrate and the coating.
[0027] The foregoing features and the operation of the invention will become more apparent in light of the following description and the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0028]
FIG. 1 is a partial sectional illustration of a component for an aircraft engine.
FIG. 2 is a schematic illustration of the engine component.
FIG. 3 is a partial illustration of a substrate of the engine component with a straight aperture.
FIG. 4 is a partial illustration of the substrate with a non-straight aperture.
FIGS. 5A-6B are schematic illustrations of various aperture patterns.
FIGS. 7A-H are partial sectional illustrations of the engine component with various aperture and coating projection configurations.
FIG. 8 is a partial sectional illustration of the engine component with another arrangement of apertures and coating projections.
FIG. 9 is a flow diagram of a method for forming the engine component.
FIG. 10 is a schematic illustration of the substrate during an electroless plating process.
FIGS. 11A and 11B are partial sectional illustrations of the engine component with multilayered coatings.
FIGS. 12A-C are partial sectional illustrations of various plated structures without underlying substrates.
FIG. 13 is a schematic sectional illustration of a gas turbine engine which may include one or more of the engine components.
DETAILED DESCRIPTION
[0029] FIG. 1 is a partial sectional illustration of a component 20 for an engine of an aircraft. Briefly, the aircraft may be configured as an airplane, a helicopter, a drone (e.g., an unmanned aerial vehicle (UAV)), a spacecraft or any other manned or unmanned aerial vehicle. The aircraft engine may be configured as a gas turbine engine, a reciprocating piston engine, a rotary engine, a hybrid-electric engine or any other type of engine capable to producing thrust and/or generating electrical power for the aircraft.
[0030] The engine component 20 may be configured as, included as part of or may otherwise include a rotor blade, a stator vane, a flowpath wall, a mount, a support structure, a casing or any other structure which would benefit from a component construction as described herein. Examples of the rotor blade include, but are not limited to, a fan blade, a propeller blade, a compressor blade and a turbine blade. Examples of the stator vane include, but are not limited to, an inlet guide vane, an outlet guide vane, a compressor vane, a turbine vane and an exhaust vane. Examples of a flowpath wall include, but are not limited to, a blade or vane platform, a blade outer air seal (also sometimes referred to as a "shroud") and a duct sidewall. Examples of the mount include, but are not limited to, a bracket, a flange and a rim. Examples of the support structure include, but are not limited to, a strut and a frame. Referring again to FIG. 1, the engine component 20 includes at least (or only) a component substrate 22 and a component coating 24.
[0031] The component substrate 22 may be configured as or included as part of a preform 26 of the engine component 20. The preform engine component 26 of FIG. 2 and its component substrate 22, for example, may have substantially the same configuration (e.g., shape, size, etc.) as the engine component 20 except, for example, being slightly undersized to accommodate the component coating 24. For example, where the engine component 20 is a rotor blade, the preform engine component 26 and its component substrate 22 may form a bare (e.g., uncoated) version of the rotor blade prior to application of the component coating 24.
[0032] The component substrate 22 of FIG. 1 includes an exterior substrate surface 28 and one or more apertures 30; e.g., blind apertures. The substrate surface 28 may form an exterior periphery of the component substrate 22 / the preform engine component 26. Each of the apertures 30 projects partially into the component substrate 22. Each aperture 30 of FIG. 1, for example, projects vertically into the component substrate 22 from the substrate surface 28 to a vertical distal end 32 of the respective aperture 30. Each aperture 30 extends laterally within the component substrate 22 between opposing lateral sides 34 of the respective aperture 30. Referring to FIG. 3, each aperture 30 may extend longitudinally into, through or within the component substrate 22 along a longitudinal centerline 36 of the respective aperture 30. Each aperture 30, for example, may be configured as a longitudinally extending slot; e.g., a groove, a channel, etc.
[0033] At least a portion or an entirety of the longitudinal centerline 36 may be straight; e.g., follow a straight trajectory. Alternatively, referring to FIG. 4, at least a portion of an entirety of the longitudinal centerline 36 may be non-straight; e.g., follow a curved, arcuate, splined and/or otherwise non-straight trajectory.
[0034] Referring to FIGS. 5A and 5B, at least some or all of the apertures 30 (schematically shown) and their respective longitudinal centerlines 36 may be arranged parallel with one another. Referring to FIGS. 6A and 6B, at least some or all of the apertures 30 (schematically shown) and their respective longitudinal centerlines 36 may also or alternatively be arranged non-parallel with one another. For example, some of the apertures 30 and the longitudinal centerlines 36 of FIG. 6A are angularly offset from (e.g., perpendicular to) and may cross or otherwise intersect others of the apertures 30 and the longitudinal centerlines 36; e.g., in a grid pattern. In another example, the apertures 30 and the longitudinal centerlines 36 of FIG. 6B may follow different trajectories. It is contemplated, of course, that the apertures 30 may be arranged in various other patterns and/or the longitudinal centerlines 36 may follow various other trajectories depending on the specific engine component specification.
[0035] The component substrate 22 of FIG. 1 is constructed from or otherwise includes a substrate material 38. This substrate material 38 may be an electrically non-conductive material such as, but not limited to, a ceramic (e.g., a thermal barrier coating such as alumina, YSZ), a polymer (e.g., a thermoplastic or thermoset material) or a non-conductive composite; e.g., a fiberglass reinforced composite. It is contemplated, however, that the substrate material 38 may alternatively be an electrically conductive material such as, but not limited to, metal or a conductive composite; e.g., a carbon fiber reinforced composite.
[0036] Referring to FIG. 1, the component coating 24 includes an exterior coating base 40 and one or more internal coating projections 42. The coating base 40 is configured to at least partially or completely cover the substrate surface 28. The coating base 40 of FIG. 1, in particular, is disposed on (e.g., contacts), bonded to and (e.g., laterally and/or longitudinally) overlaps the substrate surface 28. With this arrangement, the coating base 40 may form an exterior surface 44 of the engine component 20, which component surface 44 is disposed outward of the substrate surface 28 covered by the component coating 24 and its coating base 40. The coating base 40 may thereby form a protective coating over the component substrate 22 and its substrate surface 28; e.g., a thermal barrier coating, a wear coating, an environmental coating, etc. The component surface 44, for example, may be an exterior flowpath surface (e.g., an airfoil surface, a duct surface, etc.) of the engine component 20.
[0037] The coating projections 42 are connected to (e.g., formed integral with) the coating base 40. Each of the coating projections 42 projects vertically out from the coating base 40 and vertically into a respective one of the apertures 30 to the aperture end 32. Each of the coating projections 42 extends laterally within the respective aperture 30 between and to the opposing aperture sides 34. Each of the coating projections 42 also extend longitudinally into, through or within the respective aperture 30. Each coating projection 42 may thereby partially or completely fill the respective aperture 30. Each coating projection 42 of FIG. 1 is further disposed on, bonded to and overlaps at least one internal surface of the component substrate 22 forming the respective aperture 30. With this arrangement, the coating projection 42 may form a structural reinforcement for the coating base 40 and/or the component substrate 22. A configuration of each coating projection 42 may be tailored (e.g., sized, shaped, etc.) to tune internal stress, deflection, stiffness and/or natural frequency of the engine component 20. The coating projections 42 may also or alternatively increase adhesion between the component coating 24 and the underlying component substrate 22 by increasing surface area for bonding between the component coating 24 and the component substrate 22.
[0038] One or more or all of the coating projections 42 may each be configured to lock into the respective aperture 30. Each coating projection 42 of FIGS. 7A-H, for example, includes a web 46 (e.g., a base, an extension, etc.) and an anchor 48 (e.g., a head, a barb, a hook, etc.). The web 46 of FIGS. 7A-H projects vertically out from the coating base 40 and into the respective aperture 30 to the anchor 48. The anchor 48 may be disposed at a vertical distal end 50 of the respective coating projection 42. Referring to FIG. 7A (see also FIGS. 7B-H), each anchor 48 may have a lateral width 52 that is greater than a (e.g., constant) lateral width 54 of the web 46. With such an arrangement, one or more portions 56 of the component substrate 22 are disposed vertically between the anchor 48 and the coating base 40. In other words, one or more portions 58 (e.g., flanged, barbs, outcroppings, etc.) of the anchor 48 may project laterally out into the component substrate 22 to lock the respective coating projection 42 into place. In some embodiments, referring to FIG. 7E (see also FIGS. 7F-H), one or more additional portions 60 of the component substrate 22 may also be disposed vertically between respective portions 58 and 62 (e.g., flanges, barbs, outcroppings, etc.) of the anchor 48.
[0039] The anchor 48 may have various cross-sectional geometries such as those shown in FIGS. 7A-H. Examples of these cross-sectional geometries include, but are not limited to, a bulbous (e.g., circular) cross-sectional geometry, a semi-circular cross-sectional geometry, a trapezoidal cross-sectional geometry, a rectangular cross-sectional geometry, a chevron cross-sectional geometry as well as various other polygonal and/or curved cross-sectional geometries.
[0040] Referring to FIG. 1, the coating base 40 has a vertical thickness 64 measured from the substrate surface 28 to the component surface 44. Each coating projections 42 has a vertical height 66 measured from the coating base 40 / the substrate surface 28 to the projection distal end 50. This vertical height 66 may be equal to or greater than one-half (1/2) of the vertical thickness 64. The vertical height 66, for example, may be between one times (1x) and fifteen times (15x) the vertical thickness 64. The present disclosure, however, is not limited to the foregoing exemplary dimensional relationship as the dimensions may be changed based on application requirements and available space constraints.
[0041] In some embodiments, some or all of the coating projections 42 may be configured with a common (e.g., the same) vertical height 66. In other embodiments, referring to FIG. 8, one or more of the coating projections 42A may have a vertical height 66A that is different than a vertical height 66B of one or more other of the coating projections 42B. The coating projections 42A and 42B (generally referred to as "42") of FIG. 8, for example, are divided into multiple groups, where the coating projections 42A, 42B in each group are configured with a common vertical height 66A, 66B. In the specific embodiment of FIG. 8, the coating projections 42 in the groups are interspersed with one another; e.g., a laterally alternatively pattern of 42A and 42B. The present disclosure, however, is not limited to such an exemplary arrangement.
[0042] In some embodiments, referring to FIGS. 1 and 8, the vertical thickness 64 of the coating base 40 may be uniform (e.g., constant) laterally and/or longitudinally along the substrate surface 28. It is contemplated, however, that in other embodiments the vertical thickness 64 may change (e.g., steadily or incrementally increase, decrease, fluctuate, etc.) as the coating base 40 extends laterally and/or longitudinally along the substrate surface 28.
[0043] The component coating 24 of FIG. 1 and its members 40 and 42 are constructed from or otherwise include a coating material 68. This coating material 68 may be a metal, a ceramic (e.g., a thermal barrier coating such as alumina, YSZ) or a composite. The component coating 24, for example, may be a metal nanocoating such as a nickel (Ni) nanocoating; e.g., a nickel nano-crystalline coating.
[0044] The apertures 30 and the coating projections 42 are described above as longitudinally elongated members. The apertures 30, for example, may be configured as the longitudinally extending slots and the coating projections 42 may be configured as longitudinally extending ribs. It is contemplated, however, that any one or more or all of the apertures 30 and the corresponding coating projections 42 may each alternatively be a point feature. One or more or all of the apertures 30, for example, may alternatively be configured as a hole; e.g., a bore, a dimple, etc. Similarly, one or more or all of the coating projections 42 may alternatively be configured as a point projection; e.g., a pedestal, a hump, an arm, etc. In such embodiments, a lateral cross-sectional geometry of the element 30, 42 may be the same as (or similar to) a longitudinal cross-sectional geometry of the element 30, 42.
[0045] FIG. 9 is a flow diagram of a method 900 for manufacturing an engine component. For ease of description, the manufacturing method 900 is described with reference to the engine component 20 of FIG. 1. The manufacturing method 900 of the present disclosure, however, is not limited to manufacturing such an exemplary engine component. Furthermore, it should be understood that the term "manufacturing" herein may describe a process for forming the engine component; e.g., creating a brand new component. The term "manufacturing" may also or alternatively describe a process for repairing the engine component; e.g., restoring one or more features of a previously formed engine component to brand new condition, similar to brand new condition or better than brand new condition. The engine component, for example, may be repaired to fix one or more defects (e.g., cracks, wear and/or other damage) imparted during previous use of the engine component. The engine component may also or alternatively be repaired to fix one or more defects imparted during the initial formation of the engine component. For ease of description, however, the manufacturing method 900 is described below with respect to the initial forming of the engine component.
[0046] In step 902, the preform engine component 26 and its component substrate 22 are provided. The preform engine component 26 and its component substrate 22, for example, may be cast, machined, additively manufactured and/or otherwise formed. In some embodiments, one or more or all of the apertures 30 may be formed into the component substrate 22 during initial formation of the component substrate 22. The apertures 30, for example, may be formed by a mold during the casting of the component substrate 22. In another example, the component substrate 22 may be additively manufactured to include the apertures 30. However, in other embodiments, following formation of a body of the component substrate 22 (e.g., without the apertures 30 or with only select apertures 30), one or more or all of the apertures 30 may be formed via a machining operation to provide the preform engine component 26 and its component substrate 22.
[0047] In step 904, the component coating 24 is formed on the component substrate 22. More particularly, the coating material 68 may be applied (e.g., deposited onto) the component substrate 22 by an electroless plating process, also sometimes referred to as chemical plating or autocatalytic plating. Referring to FIG. 10, during this electroless plating process, the component substrate 22 is disposed (e.g., at least partially or completely submersed) into an electroless plating bath 70. This electroless plating bath 70 includes ions 72 of the coating material 68 in an aqueous solution 74. The coating material 68 of FIG. 1 may then be plated onto the component substrate 22 through an autocatalytic chemical reduction of the coating material ions 72 onto the component substrate 22. The coating material 68 may thereby (e.g., partially or completely) fill each of the apertures 30 as well as (e.g., partially or completely) cover the substrate surface 28. The component coating 24 including its coating base 40 and its coating projections 42 may be (e.g., completely) formed and bonded to the component substrate 22. Using the electroless plating process, the coating material 68 may be applied uniformly, to various types of substrate materials (including electrically non-conductive materials) and without requiring an electric current as is the case in electroplating. Furthermore, unlike various other deposition (e.g., chemical vapor deposition, physical vapor deposition, etc.) methods, the coating material 68 may be disposed into regions of the apertures 30 which may not have a direct line of sight.
[0048] In some embodiments, the component coating 24 and its coating members 40 and 42 may be formed (e.g., completely) by the coating material 68 through the electroless plating process. In other embodiments however, referring to FIG. 11A and 11B, the component coating 24 may be configured as a coating system with a plurality of different layers 76 and 78; e.g., a multi-layer coating. The base layer 76 of FIGS. 11A and 11B is between the component substrate 22 and the outer (e.g., top) layer 78. The base layer 76, for example, may be formed from a base layer coating material 80; e.g., the coating material 68 described above. This base layer coating material 80 may be applied and bonded (e.g., directly) to the component substrate 22 using the electroless plating process, for example, as described above. The base layer 76 and its base layer coating material 80 may thereby partially (e.g., see FIG. 11A) or completely (e.g., see FIG. 11B) fill the apertures 30 and/or (e.g., partially or completely) cover the substrate surface 28. The outer layer 78 may thereafter be formed from an outer layer coating material 82. This outer layer coating material 82 may be applied and bonded (e.g., directly) to the base layer 76 and its base layer coating material 80 again using the electroless plating process or another process such as, but not limited to, an electroplating process. The outer layer 78 and its outer layer coating material 82 may thereby partially fill the apertures 30 (e.g., see FIG. 11A), or be disposed completely outside of the apertures 30 (e.g., see FIG. 11B). The outer layer 78 and its outer layer coating material 82 may (e.g., partially or completely) cover the base layer 76 and its base layer coating material 80 and, for example, form the component surface 44. Of course, it is contemplated the component coating 24 may alternatively include one or more additional layers between the layers 76 and 78 and/or over the layers 76 and 78.
[0049] The outer layer coating material 82 may be a different material than the base layer coating material 80. This outer layer coating material 82 may be a metal, a ceramic or a composite. Examples of the metal include, but are not limited to, nickel (Ni), copper (Cu), cobalt-phosphorous or another suitable metal or metal alloy such as cobalt (Co), chromium (Cr), iron (Fe), molybdenum (Mo), titanium (Ti), tungsten (W) or zirconium (Zr). Of course, it is contemplated the outer layer coating material 82 may alternatively be the same as the base layer coating material 80, although applied in a different manner (e.g., via electroplating) for example.
[0050] In the embodiments described above, the component substrate 22 is described as part of the engine component 20. It is contemplated, however, that the component substrate 22 may alternatively be configured as a sacrificial body for forming the engine component 20. For example, the component substrate 22 may alternatively be constructed from a sacrificial material such as, but not limited to, wax, casting mold material, etc. Following formation of the component coating 24 (whether a single material coating or a multi-layer coating system), the component substrate 22 may be at least partially or completely removed to leave behind the component coating 24 - here a plated structure 84 as shown, for example, in FIGS. 12A-C. This plated structure 84 may completely define the engine component 20, or the plated structure 84 may be attached to or otherwise arranged with at least one other body to provide the engine component 20.
[0051] FIG. 13 is a schematic sectional illustration of a gas turbine engine 86 which may include one or more of the engine components 20. The engine component(s) 20, of course, may alternatively be configured for and included in various other types of engines other than the exemplary gas turbine engine of FIG. 13 as described above. Referring again to FIG. 13, the gas turbine engine 86 extends axially along an axial centerline 88 between an upstream airflow inlet 90 and a downstream airflow exhaust 92. The gas turbine engine 86 includes a fan section 94, a compressor section 95, a combustor section 96 and a turbine section 97. The turbine section 97 includes a high pressure turbine (HPT) section 97A and a low pressure turbine (LPT) section 97B; e.g., a power turbine section.
[0052] The engine sections 94-97B are arranged sequentially along the axial centerline 88 within an engine housing 98. This engine housing 98 includes an inner case 100 (e.g., a core case) and an outer case 102 (e.g., a fan case). The inner case 100 may house one or more of the engine sections 95-97B; e.g., a core of the gas turbine engine 86. The outer case 102 may house at least the fan section 94.
[0053] Each of the engine sections 94, 95, 97A and 97B includes a respective bladed rotor 104-107. Each of these bladed rotors 104-107 includes a plurality of rotor blades arranged circumferentially around and connected to one or more respective rotor disks. The rotor blades, for example, may be formed integral with or mechanically fastened, welded, brazed, adhered and/or otherwise attached to the respective rotor disk(s).
[0054] The fan rotor 104 is connected to and driven by the LPT rotor 107 through a low speed shaft 108. The compressor rotor 105 is connected to and driven by the HPT rotor 106 through a high speed shaft 110. The shafts 108 and 110 are rotatably supported by a plurality of bearings (not shown). Each of these bearings is connected to the engine housing 98 by at least one stationary structure such as, for example, an annular support strut.
[0055] During operation, air enters the gas turbine engine 86 through the airflow inlet 90. This air is directed through the fan section 94 and into a core flowpath 112 and a bypass flowpath 114. The core flowpath 112 extends sequentially through the engine sections 95-97B; e.g., the engine core. The air within the core flowpath 112 may be referred to as "core air". The bypass flowpath 114 extends through a bypass duct, which bypasses the engine core. The air within the bypass flowpath 114 may be referred to as "bypass air".
[0056] The core air is compressed by the compressor rotor 105 and directed into a combustion chamber 116 of a combustor 118 in the combustor section 96. Fuel is injected into the combustion chamber 116 and mixed with the compressed core air to provide a fuel-air mixture. This fuel-air mixture is ignited and combustion products thereof flow through and sequentially cause the HPT rotor 106 and the LPT rotor 107 to rotate. The rotation of the HPT rotor 106 drives rotation of the compressor rotor 105 and, thus, compression of the air received from a core airflow inlet. The rotation of the LPT rotor 107 drives rotation of the fan rotor 104, which propels bypass air through and out of the bypass flowpath 114. The propulsion of the bypass air may account for a majority of thrust generated by the gas turbine engine.
[0057] The gas turbine engine 86 is described above as a turbofan gas turbine engine. The present disclosure, however, is not limited to such an exemplary gas turbine engine. The gas turbine engine, for example, may alternatively be configured as a turboprop gas turbine engine, a turboshaft gas turbine engine, a turbojet gas turbine engine, an auxiliary power unit (APU) gas turbine engine or any other type of gas turbine engine or aircraft engine.
[0058] While various embodiments of the present disclosure have been described, it will be apparent to those of ordinary skill in the art that many more embodiments and implementations are possible within the scope of the disclosure. For example, the present disclosure as described herein includes several aspects and embodiments that include particular features. Although these features may be described individually, it is within the scope of the present disclosure that some or all of these features may be combined with any one of the aspects and remain within the scope of the disclosure. Accordingly, the present disclosure is not to be restricted except in light of the attached claims and their equivalents.
1. A method for manufacturing an engine component (20), the method comprising:
providing a preform engine component (26) comprising a substrate (22), the substrate (22) including a substrate surface (28) and a plurality of apertures (30), and each of the plurality of apertures (30) projecting partially into the substrate (22) from the substrate surface (28); and
forming a coating (24) on the substrate (22), the coating (24) including a base (40) and a plurality of projections (42), the base (40) covering the substrate surface (28), each of the plurality of projections (42) projecting out from the base (40) into and filling a respective one of the plurality of apertures (30), and the forming of the coating (24) comprising electroless plating a coating material (68) onto the substrate (22) over the substrate surface (28) and within the plurality of apertures (30).
2. The method of claim 1, wherein:
the electroless plating includes disposing the substrate (22) into a bath (70) of ions (72) of the coating material (68) in an aqueous solution (74); and
the coating material (68) is plated onto the substrate (22) through an autocatalytic chemical reduction of the ions (72) of the coating material (68).
3. The method of claim 1 or 2, wherein:
the coating material (68) comprises metal;
the substrate (22) comprises an electrically non-conductive material;
the coating (24) consists of the coating material (68); and/or
the engine component (20) is an aircraft engine component (20) that includes the substrate (22) and the coating (24).
4. The method of any preceding claim, wherein:
the coating (24) includes a base layer (76) and an outer layer (78);
the base layer (76) is between the substrate (22) and the outer layer (78);
the coating material (80) is electroless plated onto the substrate (22) to form the base layer (76); and
the outer layer (78) comprises a second coating material (82).
5. The method of any of claims 1 to 3, wherein:
the coating (24) includes a base layer (76) and an outer layer (78);
the coating material (80) is electroless plated onto the substrate (22) to form the base layer (76); and
the forming of the coating (24) further comprises electroplating a second coating material (82) onto the base layer (76) to form the outer layer (78).
6. The method of claim 4 or 5, wherein the coating material (80) completely fills a first
of the plurality of apertures (30).
7. The method of any of claims 4 to 6, wherein the coating material (80) and the second
coating material (82) fill a first of the plurality of apertures (30).
8. The method of any preceding claim, wherein:
the base (40) has a vertical thickness (64); and
the plurality of projections (42) comprises a first projection (42), and the first projection (42) has a vertical height (66) that is equal to or greater than one-half of the vertical thickness (64) of the base (40).
9. The method of any preceding claim, wherein:
the plurality of projections (42) comprise a first projection (42), and the first projection (42) includes a web (46) and an anchor (48);
the web (46) projects vertically out from the base (40) to the anchor (48); and
a lateral width (52) of the anchor (48) is greater than a lateral width (54) of the web (46).
10. The method of any preceding claim, wherein:
the plurality of apertures (30) comprise a first aperture (30);
the plurality of the projections (42) comprise a first projection (42), and the first projection (42) projects vertically out from the base (40) into the first aperture (30); and
a portion (56) of the substrate (22) is disposed vertically between the base (40) and a portion (58) of the first projection (42).
11. The method of claim 10, wherein a second portion (60) of the substrate (22) is disposed
vertically between the portion (58) of the first projection (42) and a second portion
(62) of the first projection (42).
12. The method of any preceding claim, wherein:
a first of the plurality of apertures (30) extends longitudinally along a first centerline (36) within the substrate (22);
a second of the plurality of apertures (30) extends longitudinally along a second centerline (36) within the substrate (22); and
at least a portion of the second centerline (36) is non-parallel with the first centerline (36).
13. The method of any preceding claim, wherein:
a first of the plurality of apertures (30) extends longitudinally along a first centerline (36) within the substrate (22); and
at least a portion of the first centerline (36) is non-straight.
14. A method for manufacturing an aircraft engine component (20), the method comprising:
providing a substrate (22) that comprises an electrically non-conductive material, the substrate (22) including a substrate surface (28) and a plurality of apertures (30), and each of the plurality of apertures (30) projecting partially vertically into the substrate (22) from the substrate surface (28); and
electroless plating a coating material (68) onto the substrate (22) to form a plated structure (84), the plated structure (84) including a base (40) and a plurality of projections (42), the base (40) covering the substrate surface (28), and each of the plurality of projections (42) projecting vertically out from the base (40) into and filling a respective one of the plurality of apertures (30). wherein the aircraft engine component (20) comprises the plated structure (84), optionally wherein:
the aircraft engine component (20) further comprises the substrate (22), and the substrate (22) forms a preform (26) of the aircraft engine component (20); and/or
the method further comprises removing the substrate (22) from the plated structure (84).
15. A method for manufacturing an engine component (20), the method comprising:
providing a substrate (22) that includes a substrate surface (28) and a plurality of apertures (30), each of the plurality of apertures (30) projecting partially vertically into the substrate (22) from the substrate surface (28);
electroless plating a coating material (68) onto the substrate (22) to form the engine component (20), the engine component (20) including a base (40) and a plurality of projections (42), the base (40) covering the substrate surface (28), and each of the plurality of projections (42) projecting vertically out from the base (40) into and filling a respective one of the plurality of apertures (30); and
removing the substrate (22) from the engine component (20).