US20250313983A1

US20250313983A1 - System and method for wet treatment of a component

Info

Publication number: US20250313983A1
Application number: US19/069,674
Authority: US
Inventors: Alpesh DESAI; Richard C. Harvey
Original assignee: Rolls Royce PLC
Current assignee: Rolls Royce PLC
Priority date: 2024-04-04
Filing date: 2025-03-04
Publication date: 2025-10-09

Abstract

A system has a chamber configured to receive and at least partially enclose at least one gas turbine engine component, at least one component support configured to support the at least one gas turbine engine component, a plurality of tanks configured to store a corresponding plurality of fluids, an electrode disposed at least partially within the chamber, a power source, at least one fluid application device configured to apply a fluid, at least one delivery valve for selectively fluidly coupling the at least one fluid application device to the plurality of tanks, at least one port configured to collect the fluid applied by the at least one fluid application device, and at least one recovery valve for selectively fluidly coupling the at least one port to the plurality of tanks.

Description

CROSS-REFERENCE TO RELATED APPLICATIONS

This specification is based upon and claims the benefit of priority from United Kingdom patent application number GB 2404771.4 filed on Apr. 4, 2024, the entire contents of which is incorporated herein by reference.

BACKGROUND

Technical Field

The present disclosure relates generally wet treating a component, more particularly, the present disclosure relates to a system and a method for wet treating a gas turbine engine component.

Description of the Related Art

Wet treatment process is a commonly used process for treatment of one or more surfaces of a component. In general, the wet treatment process may include a pre-treatment process, an etching process or a plating process, and a post-treatment process. In the pre-treatment process, a surface layer to be etched or plated may be prepared using a suitable scale conditioning fluid, following which the etching process or the plating process may be performed. During the etching process, the surface layer may be removed from the component. The etching process may include a chemical etching process or an electro-chemical etching process. The chemical etching process may be carried out by means of an acid, base, or any other chemical fluid applied to the component for a period of time. The acid, base, or the other chemical fluid may dissolve or modify the surface layer of the component. The electro-chemical etching process may be carried out by immersing the component and an electrode having opposite polarities in an electrolytic fluid. Similarly, the plating process may include an electro-chemical plating process. In the post-treatment process, a further treatment of the surface layer may be required after the etching process or the plating process, such that the surface layer is free of contamination of the chemical or electrolytic fluids.
Conventionally, the wet treatment process is accomplished using processing tanks within which an entire component, or a part of the component is submerged for a predetermined period of time, until a required surface thickness has been removed from or added to the component. The processing tanks may be difficult to maintain due to a volume of fluid contained in them. Further, heating of the fluids in the processing tanks may incur a high operational cost. Generally, such processing tanks are maintained at a predefined temperature for sustained periods of time, which may also increase operational cost of the wet treatment process. Further, using the processing tanks for the wet treatment process may also lead to loss of the fluid during the wet treatment process and may lack in process accuracy and effectiveness. Furthermore, the processing tanks are typically open and therefore, may pose related health, safety, and environment risks.

SUMMARY

According to a first aspect, there is provided a system for wet treating at least one gas turbine engine component. The system includes a chamber including a base and a plurality of sidewalls extending from the base. The chamber is configured to receive and at least partially enclose the at least one gas turbine engine component. The system further includes at least one component support configured to support the at least one gas turbine engine component within the chamber. The system further includes a plurality of tanks configured to store a corresponding plurality of fluids. At least one tank from the plurality of tanks includes an electrolytic fluid. The system further includes an electrode selectively disposed at least partially within the chamber proximal to the at least one gas turbine engine component. The system further includes a power source. The system further includes at least one fluid application device selectively fluidly coupled to the plurality of tanks. The at least one fluid application device is at least partially disposed within the chamber. The at least one fluid application device is configured to apply the fluid to the at least one gas turbine engine component. The system further includes at least one delivery valve disposed upstream of the at least one fluid application device for selectively fluidly coupling the at least one fluid application device to the plurality of tanks. The system further includes at least one port disposed in the base of the chamber. The at least one port is configured to collect the fluid applied by the at least one fluid application device. The system further includes at least one recovery valve disposed downstream of the at least one port for selectively fluidly coupling the at least one port to the plurality of tanks. The system further includes a controller communicably coupled to each of the at least one fluid application device, the at least one delivery valve, the at least one recovery valve, and the power source.
The system of the present disclosure including the controller may therefore provide the wet treatment or the surface treatment of the at least one gas turbine engine component in an automatic manner and may not require any operator. In some cases, the operator may only be required for loading or unloading of the at least one gas turbine engine component inside the chamber. Therefore, the system may reduce health, safety, and environment (HSE) risks. Further, the system may reduce use of conventional processing tanks thereby saving space in a manufacturing or processing facility. The system may also have a lower maintenance cost than that of the conventional processing tanks.
Further, in some cases, the chamber may fully enclose the at least one gas turbine engine component. The system may therefore prevent spillage of the plurality of fluids and may also prevent evaporation of the plurality of fluids in addition to reducing the HSE risks. Therefore, in some cases, the system may also reduce loss of the plurality of fluids.
Moreover, the at least one fluid application device may provide active agitation and impingement of the corresponding fluid on the at least one gas turbine engine component which may improve the wet treatment of the at least one gas turbine engine component. The at least one fluid application device may include a spray nozzle including, but not limited to, a full cone spray nozzle, a hollow cone spray nozzle, flat fan spray nozzle, solid stream spray nozzle, or the like.
Furthermore, the at least one recovery valve and the at least one port may allow the system to recover and recycle the plurality of fluids. This may further reduce loss of the plurality of fluids. Therefore, smaller tanks may be used in contrast to the conventional processing tanks.
In some embodiments, the controller is configured to select which of the plurality of tanks to selectively couple with the at least one fluid application device based on a predetermined sequence. The controller is further configured to control the at least one delivery valve, such that the selected tank is fluidly coupled with the at least one fluid application device. The controller is further configured to control the at least one fluid application device, such that the at least one fluid application device applies the corresponding fluid stored in the selected tank to the at least one gas turbine engine component. The controller is further configured to control the at least one recovery valve, such that the at least one recovery valve allows a flow of the corresponding fluid collected at the at least one port to the selected tank.
The at least one fluid application device applying the fluid to the at least one gas turbine engine component may deliver a similar, or a better result, whilst processing a lesser amount of the corresponding fluid as compared to conventional process of immersing the at least one gas turbine engine component in the conventional processing tanks for the wet treatment of the at least one gas turbine engine component. Further, the at least one fluid application device may be controlled to apply the plurality of fluids at different pressures, such that the system may achieve a desired fluid film thickness on the at least one gas turbine engine component. Further, the controller may control the at least one fluid application device to apply a mist of fluid to the at least one gas turbine engine component for uniform treatment and to further reduce usage of the corresponding fluid. This may be in conjunction with the use of an electrostatic charge to attract the mist to the at least one gas turbine engine component.
In some embodiments, when the selected tank includes the electrolytic fluid, the electrode is disposed at least partially within the chamber proximal to the at least one gas turbine engine component; the at least one fluid application device is configured to apply the electrolytic fluid to the at least one gas turbine engine component, such that the electrolytic fluid contacts the electrode and the at least one gas turbine engine component via a reservoir of the electrolytic fluid; the power source is electrically connected to the electrode and the at least one gas turbine engine component; and the controller is further configured to control the power source to provide opposite polarities to the electrode and the at least one gas turbine engine component.
Therefore, the system of the present disclosure may be used for electro-chemical processes, such as an electro-chemical plating process and an electro-chemical etching process. Specifically, for the electro-chemical plating process, the controller controls the power source to provide a negative polarity to the at least one gas turbine engine component and a positive polarity to the electrode. Further, for the electro-chemical etching process, the controller controls the power source to provide the positive polarity to the at least one gas turbine engine component and the negative polarity to the electrode.
Further, the at least one fluid application device applying the electrolytic fluid to the at least one gas turbine engine component may deliver a similar, or a better result, whilst processing a lesser amount of the electrolytic fluid as compared to conventional process of immersing the at least one gas turbine engine component in the conventional processing tanks including the electrolytic fluid for the electro-chemical processes.
In some embodiments, the system further includes a halo selectively disposed at least partially within the chamber. In some embodiments, when the selected tank includes the electrolytic fluid, the electrode is disposed at least partially within the chamber proximal to the at least one gas turbine engine component; the halo is disposed at least partially within the chamber and at least partially surrounds the at least one gas turbine engine component without contacting the at least one gas turbine engine component; the at least one fluid application device is configured to apply the electrolytic fluid to the at least one gas turbine engine component, such that the electrolytic fluid contacts the at least one gas turbine engine component, the electrode, and the halo via a reservoir of the electrolytic fluid; the power source is electrically connected to the electrode and the halo; and the controller is further configured to control the power source to provide opposite polarities to the electrode and the halo.
Therefore, the system of the present disclosure may be used for the electro-chemical processes, such as the electro-chemical plating process and the electro-chemical etching process. Specifically, for the electro-chemical plating process, the controller controls the power source to provide the positive polarity to the electrode and the negative polarity to the halo. Further, for the electro-chemical etching process, the controller controls the power source to provide the negative polarity to the electrode and the positive polarity to the halo.
The system of the present disclosure may therefore be used for both the electro-chemical plating process and the electro-chemical etching process. The system may be completed by rotation of the at least one gas turbine engine component or the halo.
In some embodiments, each of the at least one delivery valve and the at least one recovery valve may include control valves, shut-off valves, multiport valves, or the like.
In some embodiments, the system further includes a plurality of delivery conduits corresponding to the plurality of tanks. Each of the plurality of delivery conduits fluidly couples the corresponding tank to the at least one delivery valve. The system further includes a plurality of recovery conduits corresponding to the plurality of tanks. Each of the plurality of recovery conduits fluidly couples the at least one recovery valve to the corresponding tank.
The plurality of delivery conduits corresponding to the plurality of tanks provides a medium to a flow of the corresponding plurality of fluids stored in the plurality of tanks to the at least one fluid application device. The plurality of delivery conduits may allow the corresponding plurality of fluids to flow from the plurality of tanks towards the at least one fluid application device without spillage of the corresponding plurality of fluids contained in the plurality of tanks. Further, the plurality of delivery conduits may prevent cross contamination and intermixing of the corresponding plurality of fluids.
In some embodiments, the at least one delivery valve includes a single delivery valve configured to selectively fluidly couple the plurality of delivery conduits to the at least one fluid application device. Further, in some embodiments, the at least one recovery valve includes a single recovery valve configured to selectively fluidly couple the plurality of recovery conduits to the at least one port. The single delivery valve and the single recovery valve may reduce a number of gas turbine engine components of the system.
In some embodiments, the at least one delivery valve includes a plurality of delivery valves corresponding to the plurality of delivery conduits. Each delivery valve from the plurality of delivery valves is configured to selectively fluidly couple the corresponding delivery conduit to the at least one fluid application device. Further, in some embodiments, the at least one recovery valve includes a plurality of recovery valves corresponding to the plurality of recovery conduits. Each recovery valve from the plurality of recovery valves is configured to selectively fluidly couple the corresponding recovery conduit to the at least one port.
The plurality of delivery valves corresponding to the plurality of delivery conduits may ensure that only the corresponding fluid of the selected tank is applied to the at least one gas turbine engine component by the at least one fluid application device. In other words, the plurality of delivery valve corresponding to the plurality of delivery conduits may help in efficient wet treatment of the at least one gas turbine engine component by selectively controlling the flow the corresponding fluid stored in the selected tank towards the at least one gas turbine engine component by the at least one fluid application device. Further, the plurality of recovery valves corresponding to the plurality of recovery conduits may ensure proper recovery of the applied fluid drained inside the chamber towards the selected tank. Further, the plurality of delivery valve and the plurality of recovery valves may prevent cross contamination and intermixing of the plurality of fluids.
In some embodiments, the controller is communicably coupled to the at least one component support. The controller is further configured to control the at least one component support to move the at least one gas turbine engine component within the chamber while the at least one fluid application device applies the corresponding fluid stored in the selected tank to the at least one gas turbine engine component. In some examples, the at least one component support may include at least one of a jig, a rotatable gas turbine engine component, or the like configured to move the at least one gas turbine engine component in a linear, non-linear, rotary, or oscillatory motion.
The at least one component support may rotate, manipulate, or orientate the at least one gas turbine engine component inside the chamber while the at least one fluid application device applies the corresponding fluid to the at least one gas turbine engine component such that the at least one fluid application device may uniformly apply the corresponding fluid to the at least one gas turbine engine component. In other words, the at least one component support may move the at least one gas turbine engine component within the chamber such that all surface areas of the at least one gas turbine engine component may be uniformly treated.
In some embodiments, the base is inclined towards the at least one port. The inclination of the base towards the at least one port may allow the corresponding fluid to be collected at the at least one port and recovered back into the selected tank. A suction means may be used for collecting the fluid at the at least one port from the rest of the base of the chamber.
In some embodiments, the controller is further configured to control one or more parameters of the at least one fluid application device. The one or more parameters include at least one of a fluid flow rate of the at least one fluid application device, a fluid pressure of the at least one fluid application device, an opening period of the at least one fluid application device, and a droplet size of the at least one fluid application device. Controlling the one or more parameters may control an amount of the corresponding fluid applied from the at least one fluid application device. In some examples, the one or more parameters may be controlled based on requirements of the wet treatment. The amount of the corresponding fluid applied may be optimized to efficiently treat the at least one gas turbine engine component while achieving a desired thickness of the corresponding fluid over the at least one gas turbine engine component.
In some embodiments, the at least one fluid application device includes a plurality of fluid application devices. The plurality of fluid application devices may follow a profile of the at least one gas turbine engine component. The plurality of fluid application devices following the profile of the at least one gas turbine engine component may apply the corresponding fluid uniformly and optimally to the at least one gas turbine engine component. Further, the plurality of fluid application devices may uniformly treat the at least one gas turbine engine component. The at least one fluid application device may apply the fluid in a continuous laminar flow to the at least one gas turbine engine component. The continuous laminar flow of the fluid over the at least one gas turbine engine component may ensure that an inactive layer of spent fluid does not build up on the at least one gas turbine engine component. In some cases, the plurality of fluid application devices may include similar type of fluid application devices. However, in some other cases, the plurality of fluid application devices may include different types of fluid application devices, as per desired application attributes.
In some embodiments, the system further includes a heating device disposed upstream of the at least one fluid application device. The heating device is configured to heat and store the corresponding fluid before the at least one fluid application device applies the corresponding fluid stored in the selected tank to the at least one gas turbine engine component. The heating device may heat the corresponding fluid in case the corresponding fluid may be required to be heated for the wet treatment. In contrast to heating the corresponding fluid stored in the conventional processing tank, the heating device may only heat a lesser amount of the corresponding fluid and for a shorter interval of time, thus, saving operational cost of the system. This may further reduce consumption of heating energy thereby reducing the operating cost of the system.
In some embodiments, the system further includes at least one syphon conduit configured to remove the corresponding fluid applied by the at least one fluid application device to the at least one gas turbine engine component. The at least one syphon conduit is further configured to transport the corresponding fluid removed from the at least one gas turbine engine component to the at least one port. Therefore, the at least one syphon conduit may automatically remove and transport the corresponding fluid applied by the at least one fluid application device from the at least one gas turbine engine component to the at least one port.
In some embodiments, the power source includes a rectifier. In some cases, the rectifier may be configured to convert an alternating current (AC) into a direct current (DC). The rectifier may be used where steady flow of a DC current is required.
According to a second aspect, there is provided a method for wet treatment of at least one gas turbine engine component. The method includes providing a chamber including a base and a plurality of sidewalls extending from the base. The chamber is configured to receive and at least partially enclose the at least one gas turbine engine component. The method further includes providing at least one component support configured to support the at least one gas turbine engine component within the chamber. The method further includes providing a plurality of tanks configured to store a corresponding plurality of fluids. At least one tank from the plurality of tanks includes an electrolytic fluid. The method further includes selectively providing an electrode at least partially within the chamber proximal to the at least one gas turbine engine component. The method further includes providing a power source. The method further includes providing at least one fluid application device selectively fluidly coupled to the plurality of tanks. The at least one fluid application device is at least partially disposed within the chamber. The at least one fluid application device is configured to apply a fluid to the at least one gas turbine engine component. The method further includes providing at least one delivery valve disposed upstream of the at least one fluid application device for selectively fluidly coupling the at least one fluid application device to the plurality of tanks. The method further includes providing at least one port disposed in the base of the chamber. The at least one port is configured to collect the fluid applied by the at least one fluid application device. The method further includes providing at least one recovery valve disposed downstream of the at least one port for selectively fluidly coupling the at least one port to the plurality of tanks.
In some embodiments, the method further includes selecting which of the plurality of tanks to selectively couple with the at least one fluid application device based on a predetermined sequence. The method further includes controlling the at least one delivery valve, such that the selected tank is fluidly coupled with the at least one fluid application device. The method further includes controlling the at least one fluid application device, such that the at least one fluid application device applies the corresponding fluid stored in the selected tank to the at least one gas turbine engine component. The method further includes controlling the at least one recovery valve, such that the at least one recovery valve allows a flow of the corresponding fluid collected at the at least one port to the selected tank.
In some embodiments, the method further includes, when the selected tank includes the electrolytic fluid, providing the electrode at least partially within the chamber proximal to the at least one gas turbine engine component; applying the electrolytic fluid to the at least one gas turbine engine component, such that the electrolytic fluid contacts the electrode and the at least one gas turbine engine component via a reservoir of the electrolytic fluid; electrically connecting the power source to the electrode and the at least one gas turbine engine component; and controlling the power source to provide opposite polarities to the electrode and the at least one gas turbine engine component.
In some embodiments, the method further includes, when the selected tank includes the electrolytic fluid, providing the electrode at least partially within the chamber proximal to the at least one gas turbine engine component; providing a halo at least partially within the chamber and at least partially surrounding the at least one gas turbine engine component without contacting the at least one gas turbine engine component; applying the electrolytic fluid to the at least one gas turbine engine component, such that the electrolytic fluid contacts the at least one gas turbine engine component, the electrode, and the halo via a reservoir of the electrolytic fluid; electrically connecting the power source to the electrode and the halo; and controlling the power source to provide opposite polarities to the electrode and the halo.
In some embodiments, the method further includes providing a plurality of delivery conduits corresponding to the plurality of tanks. Each of the plurality of delivery conduits fluidly couples the corresponding tank to the at least one delivery valve. The method further includes providing a plurality of recovery conduits corresponding to the plurality of tanks. Each of the plurality of recovery conduits fluidly couples the at least one recovery valve to the corresponding tank.
In some embodiments, the at least one delivery valve includes a single delivery valve. In some embodiments, controlling the at least one delivery valve further includes controlling the single delivery valve to selectively fluidly couple each of the plurality of delivery conduits to the at least one fluid application device. In some embodiments, the at least one recovery valve includes a single recovery valve. In some embodiments, controlling the at least one recovery valve further includes controlling the single recovery valve to selectively fluidly couple each of the plurality of recovery conduits to the at least one port.
In some embodiments, the at least one delivery valve includes a plurality of delivery valves corresponding to the plurality of delivery conduits. In some embodiments, controlling the at least one delivery valve further includes controlling each delivery valve from the plurality of delivery valves to selectively fluidly couple the corresponding delivery conduit to the at least one fluid application device. In some embodiments, the at least one recovery valve includes a plurality of recovery valves corresponding to the plurality of recovery conduits. In some embodiments, controlling the at least one recovery valve further includes controlling each recovery valve from the plurality of recovery valves to selectively fluidly couple the corresponding recovery conduit to the at least one port.
In some embodiments, the method further includes controlling the at least one component support to move the at least one gas turbine engine component within the chamber while the at least one fluid application device applies the corresponding fluid stored in the selected tank to the at least one gas turbine engine component.
In some embodiments, the method further includes controlling one or more parameters of the at least one fluid application device. The one or more parameters include at least one of a fluid flow rate of the at least one fluid application device, a fluid pressure of the at least one fluid application device, an opening period of the at least one fluid application device, and a droplet size of the at least one fluid application device.
In some embodiments, the method further includes heating and storing the corresponding fluid before the at least one fluid application device applies the corresponding fluid stored in the selected tank to the at least one gas turbine engine component.
In some embodiments, the method further includes removing the corresponding fluid applied by the at least one fluid application device from the at least one gas turbine engine component. The method further includes transporting the corresponding fluid removed from the at least one gas turbine engine component to the at least one port.
In some embodiments, the chamber may be heated, or heated jets or warmed air may be directed at the parts to aid drying prior to being unloaded from the chamber.
In some embodiments, compressed air may be applied to aid drying of the parts or to accelerate the draining of the fluid from the parts or chamber.

BRIEF DESCRIPTION OF THE DRAWINGS

Embodiments will now be described by way of example only, with reference to the Figures, in which:

FIG. 1 is a schematic front view of a system for wet treating at least one gas turbine engine component, according to an embodiment of the present disclosure;

FIG. 2A is an enlarged schematic view of a section X of the system of FIG. 1 ;

FIG. 2B is an enlarged schematic view of a section Y of the system of FIG. 1 ;

FIG. 3 is a schematic view of the system of FIG. 1 ;

FIG. 4 is a schematic view of the system of FIG. 1 , according to another embodiment of the present disclosure;

FIG. 5 is a schematic front view of a system for the wet treatment of the at least one gas turbine engine component, according to another embodiment of the present disclosure;

FIG. 6A is an enlarged schematic view of a portion of the system of FIG. 5 ;

FIG. 6B is an enlarged schematic view of another portion of the system of FIG. 5 ;

FIG. 7 is a schematic front view of a system for the wet treatment of the at least one gas turbine engine component, according to yet another embodiment of the present disclosure;

FIG. 8 is a flow chart for a method for the wet treatment of the at least one gas turbine engine component;

FIG. 9A shows images of an exemplary experimental setup and its components for an application trial of an electro-chemical plating process; and

FIG. 9B shows images of a gas turbine engine component before and after the application trial.

DETAILED DESCRIPTION

Aspects and embodiments of the present disclosure will now be discussed with reference to the accompanying Figures. Further aspects and embodiments will be apparent to those skilled in the art.
FIG. 1 illustrates a schematic front view of a system 100 for wet treatment of at least one gas turbine engine component 102, according to an embodiment of the present disclosure. In the illustrated embodiment of FIG. 1 , the at least one gas turbine engine component 102 is a single gas turbine engine component. However, in some other embodiments, the at least one gas turbine engine component 102 may include a plurality of gas turbine engine components. In some embodiments, the at least one gas turbine engine component 102 of the gas turbine engine may be a bladed disk drum or a fan blade.
The system 100 includes a chamber 104. Specifically, the system 100 includes a housing 110 defining the chamber 104. The chamber 104 includes a base 106 and a plurality of sidewalls 108 extending from the base 106. The chamber 104 is configured to receive and at least partially enclose the at least one gas turbine engine component 102. In other words, the housing 110 of the chamber 104 receives and at least partially encloses the at least one gas turbine engine component 102.
The system 100 is manufactured using materials suitable for the manufacture of wet processing systems, and for a chemistry being applied. In some examples, the chamber 104 may be made of a metallic material, a polymeric material, a ceramic material, or a combination thereof. In some other examples, the chamber 104 may be made of, but not limited to, stainless steel, quartz, or alumina. In some other examples, the system 100 may include several chambers (e.g., the chamber 104), for enabling different wet treatment processes on the at least one gas turbine engine component 102. Further, the chambers may be manufactured of different materials that may allow different types of the wet treatment processes.
The system 100 further includes at least one component support 112 configured to support the at least one gas turbine engine component 102 within the chamber 104. In the illustrated embodiment of FIG. 1 , the system 100 includes one component support 112 configured to support the gas turbine engine component 102. However, any number or type of the at least one component support 112 may be used to support the corresponding gas turbine engine component 102 based on desired application attributes. For example, the at least one component support 112 may include at least one of a jig, a rotatable gas turbine engine component, a support fixture, a hanging support, or the like.
The system 100 further includes a plurality of tanks 114 configured to store a corresponding plurality of fluids 116. At least one tank from the plurality of tanks 114 includes an electrolytic fluid 117. In other words, at least one of the plurality of fluids 116 includes the electrolytic fluid 117. In some cases, the plurality of fluids 116 may be collectively or individually referred to hereinafter as “the fluid 116”.
In the illustrated embodiment of FIG. 1 , the plurality of tanks 114 includes three tanks. Specifically, the plurality of tanks 114 includes a first tank 114-1, a second tank 114-2, and a third tank 114-3. However, the plurality of tanks 114 may include any number of tanks based on desired application attributes. Further, the corresponding plurality of fluids 116 includes three fluids. Specifically, the corresponding plurality of fluids 116 includes a first fluid 116-1, a second fluid 116-2, and the electrolytic fluid 117. Particularly, the first tank 114-1 may be configured to store the first fluid 116-1. The second tank 114-2 may be configured to store the second fluid 116-2. The third tank 114-3 may be configured to store the electrolytic fluid 117. Further, in some embodiments, each of the first, second, and third tanks 114-1, 114-2, 114-3 from the plurality of tanks 114 may be identical or similar in shape and size. However, in some other embodiments, each of the first, second, and third tanks 114-1, 114-2, 114-3 from the plurality of tanks 114 may be different in shape and size, as per desired application attributes.
In some examples, the plurality of fluids 116 may include acid or alkali solutions. For example, the plurality of fluids 116 may include hydrofluorosilicic (H₂SiF₆) acid, nitric (HNO₃) acid, hydrofluoric (HF) acid, water, a detergent solution, a scale conditioner, etchant fluid pastes, or a combination of the above. In some embodiments, the plurality of fluids 116 may be used for the surface treatment of the at least one gas turbine engine component 102. In some embodiments, the plurality of fluids 116 may be used for rinsing, cleaning, and neutralising the at least one gas turbine engine component 102. In some embodiments, the system 100 may be used to prepare parts and apply fluids for non-destructive fluorescent penetrant inspection. As discussed above, at least one of the plurality of fluids 116 includes the electrolytic fluid 117.
The system 100 further includes an electrode 136 selectively disposed at least partially within the chamber 104 proximal to the at least one gas turbine engine component 102. The system 100 further includes a power source 138. In some embodiments, the power source 138 includes a rectifier 140.
The system 100 further includes at least one fluid application device 118 selectively fluidly coupled to the plurality of tanks 114. The at least one fluid application device 118 is at least partially disposed within the chamber 104. The at least one fluid application device 118 is configured to apply the fluid 116 to the at least one gas turbine engine component 102. In some embodiments, the at least one fluid application device 118 may include a spray nozzle including, but not limited to, a full cone spray nozzle, a hollow cone spray nozzle, flat fan spray nozzle, solid stream spray nozzle, or the like.
In some embodiments, the at least one fluid application device 118 includes a plurality of fluid application devices 118. In some embodiments, the plurality of fluid application devices 118 follows a profile of the at least one gas turbine engine component 102. In some examples, the plurality of fluid application devices 118 may follow the profile of the at least one gas turbine engine component 102 such that the plurality of fluid application devices 118 may apply the fluid 116 uniformly and optimally to the at least one gas turbine engine component 102.
In the illustrated embodiment of FIG. 1 , the at least one fluid application device 118 includes three fluid application devices 118. Specifically, the at least one fluid application device 118 includes a first fluid application device 118-1, a second fluid application device 118-2, and a third fluid application device 118-3. However, it should be noted that the system 100 may include any number of fluid application devices 118 based on desired application attributes. For example, the at least one fluid application device 118 may include a number of fluid application devices that may be required to follow the profile of the at least one gas turbine engine component 102 and apply the fluid 116 uniformly to the at least one gas turbine engine component 102.
The plurality of fluid application devices 118 following the profile of the at least one gas turbine engine component 102 may ensure that the wet treatment is uniform at all surface areas of the at least one gas turbine engine component 102. Thus, the plurality of fluid application devices 118 may properly treat the at least one gas turbine engine component 102. The at least one fluid application device 118 may apply the fluid 116 in a continuous laminar flow to the at least one gas turbine engine component 102. The continuous laminar flow of the fluid 116 to the at least one gas turbine engine component 102 may ensure that an inactive layer of the fluid 116 does not build up on the at least one gas turbine engine component 102.
As discussed above, the at least one fluid application device 118 is configured to apply the fluid 116 to the at least one gas turbine engine component 102. Specifically, each of the first fluid application device 118-1, the second fluid application device 118-2, and the third fluid application device 118-3 is configured to apply the first fluid 116-1, the second fluid 116-2, and the electrolytic fluid 117 stored in the first tank 114-1, the second tank 114-2, and the third tank 114-3, respectively, to the at least one gas turbine engine component 102. In some examples, the at least one gas turbine engine component 102 may be electrostatically or electrically charged to improve the wet treatment of the at least one gas turbine engine component 102. Specifically, the fluid 116 being applied and the at least one gas turbine engine component 102 may be electrostatically or electrically charged with opposite charges to improve the wet treatment of the at least one gas turbine engine component 102.
The system 100 further includes at least one delivery valve 120 disposed upstream of the at least one fluid application device 118 for selectively fluidly coupling the at least one fluid application device 118 to the plurality of tanks 114. In some embodiments, the at least one delivery valve 120 may include control valves, shut-off valves, multiport valves, or the like.
In the illustrated embodiment of FIG. 1 , the at least one delivery valve 120 includes three delivery valves 120. Further, the three delivery valves 120 are disposed upstream of the first fluid application device 118-1, the second fluid application device 118-2, and the third fluid application device 118-3, respectively. Each delivery valve 120 selectively couples the at least one fluid application device 118 to one of the plurality of tanks 114. For example, the delivery valve 120 disposed upstream of the first fluid application device 118-1 may selectively couple the first fluid application device 118-1 to one of the first tank 114-1, the second tank 114-2, and the third tank 114-3.
In some embodiments, the system 100 further includes a plurality of delivery conduits 122 corresponding to the plurality of tanks 114. In the illustrated embodiment of FIG. 1 , the plurality of delivery conduits 122 includes nine delivery conduits 122. In some embodiments, each of the plurality of delivery conduits 122 fluidly couples the corresponding tank 114 to the at least one delivery valve 120. In the illustrated embodiment of FIG. 1 , the plurality of conduits 122 fluidly couples the first tank 114-1, the second tank 114-2, and the third tank 114-3 to each of the plurality of delivery valves 120 disposed upstream of the first fluid application device 118-1, the second fluid application device 118-2, and the third fluid application device 118-3. It should be noted that a number of the delivery conduits 122 may vary based on the number of tanks 114 and/or the number of delivery valves 120.
In some examples, the plurality of delivery conduits 122 corresponding to the plurality of tanks 114 provides a medium to a flow of the corresponding plurality of fluids 116 stored in the plurality of tanks 114 to the at least one fluid application device 118. The plurality of delivery conduits 122 may allow the fluid 116 to flow from the selected tank 114 towards the at least one fluid application device 118 without spillage of the corresponding plurality of fluids 116 contained in the plurality of tanks 114. Further, the plurality of delivery conduits 122 may prevent cross contamination and intermixing of the corresponding plurality of fluids 116.
FIG. 2A is an enlarged schematic view of a section X (shown in FIG. 1 ) of the system 100 shown in FIG. 1 , according to an embodiment of the present disclosure. The at least one delivery valve 120 is configured to selectively fluidly couple the plurality of delivery conduits 122 to the at least one fluid application device 118. Specifically, as illustrated in FIG. 2A, the delivery valve 120 disposed upstream of the first fluid application device 118-1 is configured to fluidly couple one of the plurality of conduits 122 to the first fluid application device 118-1 to apply one of the corresponding plurality of fluids 116 to the at least one gas turbine engine component 102. Similarly, the delivery valve 120 disposed upstream of the second fluid application device 118-2 (shown in FIG. 1 ) is configured to fluidly couple one of the plurality of conduits 122 to the second fluid application device 118-2 to apply the same one of the corresponding plurality of fluids 116 to the at least one gas turbine engine component 102, and the delivery valve 120 disposed upstream of the third fluid application device 118-3 (shown in FIG. 1 ) is configured to fluidly couple one of the plurality of conduits 122 to the third fluid application device 118-3 to apply the same one of the corresponding plurality of fluids 116 to the at least one gas turbine engine component 102.
Referring again to FIG. 1 , the system 100 further includes at least one port 124 disposed in the base 106 of the chamber 104. The at least one port 124 is configured to collect the fluid 116 applied by the at least one fluid application device 118. In some embodiments, the base 106 is inclined towards the at least one port 124. The inclination of the base 106 towards the at least one port 124 may allow the fluid 116 applied by the at least one fluid application device 118 to flow towards the at least one port 124 and collect at the at least one port 124. Particularly, in the illustrated embodiment of FIG. 1 , the system 100 includes a single port 124 which is configured to collect the first fluid 116-1, the second fluid 116-2, or the electrolytic fluid 117 after being applied by the first fluid application device 118-1, the second fluid application device 118-2, and the third fluid application device 118-3. A suction means (e.g., at least one syphon conduit 130) may be used for collecting the fluid 116 at the at least one port 124 from the rest of the base 106 of the chamber 104.
The system 100 further includes at least one recovery valve 126 disposed downstream of the at least one port 124 for selectively fluidly coupling the at least one port 124 to the plurality of tanks 114. In some embodiments, the at least one recovery valve 126 may include control valves, shut-off valves, multiport valves, or the like.
In the illustrated embodiment of FIG. 1 , the at least one recovery valve 126 includes a single recovery valve 126 to selectively fluidly couple the at least one port 124 to one of the plurality of tanks 114. Specifically, the single recovery valve 126 selectively fluidly couples the at least one port 124 to one of the first tank 114-1, the second tank 114-2, and the third tank 114-3.
In some embodiments, the system 100 further includes a plurality of recovery conduits 128 corresponding to the plurality of tanks 114. In some embodiments, each of the plurality of recovery conduits 128 fluidly couples the at least one recovery valve 126 to the corresponding tank 114. In the illustrated embodiment of FIG. 1 , the plurality of recovery conduits 128 includes three recovery conduits 128 that fluidly couple the recovery valve 126 to the first tank 114-1, the second tank 114-2 and the third tank 114-3, respectively. A number of the recovery conduits 128 may vary based on the number of tanks 114 and/or the number of recovery valve 126. In some examples, the plurality of recovery conduits 128 may allow recovery of the fluid 116 collected at the at the at least one port 124 to the corresponding tank 114.
FIG. 2B is an enlarged schematic view of a section Y (shown in FIG. 1 ) of the system 100 shown in FIG. 1 , according to an embodiment of the present disclosure. The at least one recovery valve 126 is configured to selectively fluidly couple the plurality of recovery conduits 128 to the at least one port 124.
Referring again to FIG. 1 , the system 100 further includes a controller 134 communicably coupled to each of the at least one fluid application device 118, the at least one delivery valve 120, the at least one recovery valve 126, and the power source 138. Specifically, in the illustrated embodiment of FIG. 1 , the controller 134 is communicably coupled to each of the first fluid application device 118-1, the second fluid application device 118-2, the third fluid application device 118-3, the three delivery valves 120, the at least one recovery valve 126, and the power source 138.
The controller 134 may include one or more processors and one or more memories. It should be noted that the one or more processors may embody a single microprocessor or multiple microprocessors for receiving various input signals. Numerous commercially available microprocessors may be configured to perform the functions of the one or more processors. Each processor may further include a general processor, a central processing unit, an application specific integrated circuit (ASIC), a digital signal processor, a field programmable gate array (FPGA), a digital circuit, an analog circuit, a controller, a microcontroller, any other type of processor, or any combination thereof. Each processor may include one or more gas turbine engine components that may be operable to execute computer executable instructions or computer code that may be stored and retrieved from the one or more memories.
In some embodiments, the controller 134 may be used to monitor health parameters of the corresponding plurality of fluids 116 inside the plurality of tanks 114. In some embodiments, the health parameters may be monitored by measuring titration, conductivity, concentration, and cleanliness of the corresponding plurality of fluids 116 inside the plurality of tanks 114. In some examples, the controller 134 may generate an alert or an alarm when one or more of the health parameters cross corresponding threshold levels and can affect the wet treatment process of the at least one gas turbine engine component 102.
In some embodiments, the controller 134 is configured to select which of the plurality of tanks 114 to selectively couple with the at least one fluid application device 118 based on a predetermined sequence. Particularly, the controller 134 is configured to select which of the plurality of tanks 114, i.e., the first tank 114-1, the second tank 114-2, or the third tank 114-3 to selectively couple with the first fluid application device 118-1, the second fluid application device 118-2, and the third fluid application device 118-3 based on the predetermined sequence. The predetermined sequence may be based on the requirements for a particular wet treatment of the at least one gas turbine engine component 102. For example, the controller 134 may select the first tank 114-1 to selectively couple with the first fluid application device 118-1, the second fluid application device 118-2, and the third fluid application device 118-3 based on the predetermined sequence.
In some embodiments, the controller 134 is further configured to control the at least one delivery valve 120, such that the selected tank 114 is fluidly coupled with the at least one fluid application device 118. In other words, the controller 134 is configured to control each delivery valve 120 such that the selected tank 114, i.e., any one of the first tank 114-1, the second tank 114-2, and the third tank 114-3 is fluidly coupled with the first fluid application device 118-1, the second fluid application device 118-2, and the third fluid application device 118-3. For example, the controller 134 may control the at least one delivery valve 120, such that the selected tank 114 (e.g., the first tank 114-1) is fluidly coupled with the first fluid application device 118-1, the second fluid application device 118-2, and the third fluid application device 118-3.
In some embodiments, the controller 134 is further configured to control the at least one fluid application device 118, such that the at least one fluid application device 118 applies the corresponding fluid 116 stored in the selected tank 114 to the at least one gas turbine engine component 102. For example, the controller 134 may control the first fluid application device 118-1, the second fluid application device 118-2, and the third fluid application device 118-3, such that the first fluid application device 118-1, the second fluid application device 118-2, and the third fluid application device 118-3 apply the first fluid 116-1 stored in the first tank 114-1 to the at least one gas turbine engine component 102.
In some embodiments, the controller 134 is further configured to control one or more parameters of the at least one fluid application device 118. The one or more parameters include at least one of a fluid flow rate of the at least one fluid application device 118, a fluid pressure of the at least one fluid application device 118, an opening period of the at least one fluid application device 118, and a droplet size of the at least one fluid application device 118. In the illustrated embodiment of FIG. 1 , the controller 134 is configured to control one or more parameters of the first fluid application device 118-1, the second fluid application device 118-2, and the third fluid application device 118-3. In some examples, controlling the one or more parameters may control an amount of the corresponding fluid 116 applied from the at least one fluid application device 118. In some examples, the one or more parameters may be controlled based on requirements of the wet treatment. The amount of the corresponding fluid 116 applied may be optimized to treat the at least one gas turbine engine component 102 while achieving a desired thickness of the corresponding fluid 116 over the at least one gas turbine engine component 102.
The at least one fluid application device 118 applying the corresponding fluid 116 to the at least one gas turbine engine component 102 may deliver a similar, or a better result, whilst using a lesser amount of the corresponding fluid 116 as compared to conventional process of immersing the at least one gas turbine engine component 102 in processing tanks for the wet treatment of the at least one gas turbine engine component 102. Further, the at least one fluid application device 118 may be controlled to apply the plurality of fluids 116 at different pressures, such that the system 100 may achieve a desired fluid film thickness on the at least one gas turbine engine component 102. Further, the controller 134 may control the at least one fluid application device 118 to apply mists of the corresponding fluid 116 to the at least one gas turbine engine component 102 for uniform treatment and to further reduce usage of the corresponding fluid 116.
In some embodiments, the controller 134 is communicably coupled to the at least one component support 112. The controller 134 is further configured to control the at least one component support 112 to move the at least one gas turbine engine component 102 within the chamber 104 while the at least one fluid application device 118 applies the corresponding fluid 116 stored in the selected tank 114 to the at least one gas turbine engine component 102. In other words, the controller 134 is configured to control the at least one component support 112 to move the at least one gas turbine engine component 102 within the chamber 104 while the first fluid application device 118-1, the second fluid application device 118-2, and the third fluid application device 118-3 apply the corresponding fluid 116, i.e., the first fluid 116-1 stored in the first tank 114-1, the second fluid 116-2 stored in the second tank 114-2, or the electrolytic fluid 117 stored in the third tank 114-3. In some examples, the at least one component support 112 may be configured to move the at least one gas turbine engine component 102 in a linear, non-linear, rotary, or oscillatory motion.
In some examples, the at least one component support 112 may rotate, manipulate, or orientate the at least one gas turbine engine component 102 inside the chamber 104 while the at least one fluid application device 118 applies the corresponding fluid 116 to the at least one gas turbine engine component 102 such that the at least one fluid application device 118 may uniformly apply the corresponding fluid 116 on all surfaces of the at least one gas turbine engine component 102. In other words, the at least one component support 112 may move the at least one gas turbine engine component 102 within the chamber 104 such that all surface areas of the at least one gas turbine engine component 102 may be uniformly treated.
In some embodiments, the controller 134 is further configured to control the at least one recovery valve 126, such that the at least one recovery valve 126 allows a flow of the corresponding fluid 116 collected at the at least one port 124 to the selected tank 114. In the illustrated embodiment of FIG. 1 , the controller 134 is further configured to control the single recovery valve 126, such that the single recovery valve 126 allows the flow of the corresponding fluid 116 to the selected tank 114, i.e., the first fluid 116-1 to the first tank 114-1, the second fluid 116-2 to the second tank 114-2, and the electrolytic fluid 117 to the third tank 114-3. Therefore, the at least one recovery valve 126 may prevent cross contamination and intermixing of the plurality of fluids 116 before flowing to the respective tanks 114.
In some embodiments, the system 100 further includes a heating device 132 disposed upstream of the at least one fluid application device 118. In the illustrated embodiment of FIG. 1 , the heating device 132 is disposed upstream of the first fluid application device 118-1. However, in some other embodiments, the heating device 132 may be disposed upstream of each of the first, second, and third fluid application devices 118-1, 118-2, 118-3. The heating device 132 is configured to heat and store the corresponding fluid 116, before the at least one fluid application device 118 applies the corresponding fluid 116 stored in the selected tank 114 to the at least one gas turbine engine component 102. For example, the heating device 132 may heat and store the first fluid 116-1 before the first fluid application device 118-1 applies the first fluid 116-1 stored in the first tank 114-1 to the at least one gas turbine engine component 102. In some examples, the heating device 132 may include an electric heater. In some other examples, the heating device 132 may include any other suitable heating means or energy source such as a heating rod or a heating coil to heat the corresponding fluid 116.
In some examples, the corresponding fluid 116 (e.g., one or more of the plurality of fluids 116) may be required to be heated for the wet treatment. The heating device 132 may heat the corresponding fluid 116 before the at least one fluid application device 118 applies the corresponding fluid 116. In contrast to heating the corresponding fluid 116 stored in a conventional processing tank, the heating device 132 may only heat a lesser amount of the corresponding fluid 116 and for a shorter interval of time, thus, saving operational cost of the system 100. This may further reduce consumption of energy thereby saving about 80% of energy consumption for operating the system 100.
In some embodiments, the system 100 further includes the at least one syphon conduit 130 configured to remove the corresponding fluid 116 applied by the at least one fluid application device 118 to the at least one gas turbine engine component 102. In some embodiments, the at least one syphon conduit 130 is further configured to transport the corresponding fluid 116 removed from the at least one gas turbine engine component 102 to the at least one port 124. For example, the at least one gas turbine engine component 102 may have a complex shape/profile and the corresponding fluid 116 may get trapped in areas which may be difficult to drain. In such cases, the at least one syphon conduit 130 may remove the corresponding fluid 116 applied by the at least one fluid application device 118 from such areas.
Therefore, the at least one syphon conduit 130 may automatically remove and transport the corresponding fluid 116 applied by the at least one fluid application device 118 from the at least one gas turbine engine component 102 to the at least one port 124. This may minimize human intervention. In some examples, the system 100 may reverse the at least one fluid application device 118, such that the at least one fluid application device 118 may act as a syphon to recover the corresponding fluid 116 that is trapped in such areas.
In some examples, after the wet treatment of the at least one gas turbine engine component 102, the at least one gas turbine engine component 102 may be transported from the chamber 104 through a transporter, or a carrier system (not shown). In some embodiments, the system 100 may be operated separately, or in conjunction with conventional wet process lines to complete all required wet treatment processes for the at least one gas turbine engine component 102.
The system 100 may therefore provide the wet treatment of the at least one gas turbine engine component 102 in an automatic manner and may not require any operator. In some cases, the operator may only be required for loading or unloading of the at least one gas turbine engine component 102 inside the chamber 104. Therefore, the system 100 may reduce health, safety, and environment (HSE) risks. Further, the system 100 may eliminate the use of the conventional processing tanks thereby saving space in a manufacturing or processing facility. The system 100 may also have a lower maintenance cost than that of the conventional processing tanks.
Further, in some cases, the chamber 104 may fully enclose the at least one gas turbine engine component 102. The system 100 may therefore prevent spillage of the plurality of fluids 116 and may also prevent evaporation of the plurality of fluids 116 in addition to reducing the HSE risks. Therefore, in some cases, the system 100 may also reduce loss of the plurality of fluids.
Moreover, the at least one fluid application device 118 may provide active agitation and impingement of the corresponding fluid 116 on the at least one gas turbine engine component 102 which may improve the wet treatment of the at least one gas turbine engine component 102.
Furthermore, the at least one recovery valve 126 and the at least one port 124 may allow the system 100 to recover and recycle the plurality of fluids 116. This may further reduce loss of the plurality of fluids 116. Therefore, smaller tanks may be used in contrast to the conventional processing tanks.
FIG. 3 is a schematic view of the system 100, according to an embodiment of the present disclosure. In the illustrated embodiment of FIG. 3 , when the selected tank 114 includes the electrolytic fluid 117, the electrode 136 is disposed at least partially within the chamber 104 proximal to the at least one gas turbine engine component 102.
Further, when the selected tank 114 includes the electrolytic fluid 117, the at least one fluid application device 118 is configured to apply the electrolytic fluid 117 to the at least one gas turbine engine component 102, such that the electrolytic fluid 117 contacts the electrode 136 and the at least one gas turbine engine component 102 via a reservoir 119 of the electrolytic fluid 117.
Furthermore, when the selected tank 114 includes the electrolytic fluid 117, the power source 138 is electrically connected to the electrode 136 and the at least one gas turbine engine component 102.
Moreover, when the selected tank 114 includes the electrolytic fluid 117, the controller 134 is further configured to control the power source 138 to provide opposite polarities to the electrode 136 and the at least one gas turbine engine component 102.
Specifically, for an electro-chemical etching process, the selected tank 114 includes the electrolytic fluid 117, and the controller 134 is further configured to control the power source 138 to provide a negative polarity to the electrode 136 and provide a positive polarity to the at least one gas turbine engine component 102. In other words, for the electro-chemical etching process, the selected tank 114 includes the electrolytic fluid 117, the electrode 136 is a cathode, and the at least one gas turbine engine component 102 is an anode.
Further, for an electro-chemical plating process, the selected tank 114 includes the electrolytic fluid 117, and the controller 134 is further configured to control the power source 138 to provide the positive polarity to the electrode 136 and provide the negative polarity to the at least one gas turbine engine component 102. In other words, for the electro-chemical plating process, the selected tank 114 includes the electrolytic fluid 117, the electrode 136 is the anode, and the at least one gas turbine engine component 102 is the cathode.
Therefore, the system 100 may be used for the electro-chemical processes, such as the electro-chemical plating process and the electro-chemical etching process. Furthermore, the at least one fluid application device 118 applying the electrolytic fluid 117 to the at least one gas turbine engine component 102 may deliver a similar, or a better result, whilst processing a lesser amount of the electrolytic fluid 117 as compared to a conventional process of immersing the at least one gas turbine engine component 102 in the conventional processing tanks including the electrolytic fluid 117 for the electro-chemical processes.
FIG. 4 is a schematic view of the system 100, according to another embodiment of the present disclosure. In the illustrated embodiment of FIG. 4 , the system 100 further includes a halo 137 selectively disposed at least partially within the chamber 104.
As shown in FIG. 4 , when the selected tank 114 includes the electrolytic fluid 117, the electrode 136 is disposed at least partially within the chamber 104 proximal to the at least one gas turbine engine component 102. Further, when the selected tank 114 includes the electrolytic fluid 117, the halo 137 is disposed at least partially within the chamber 104 and at least partially surrounds the at least one gas turbine engine component 102 without contacting the at least one gas turbine engine component 102.
Furthermore, when the selected tank 114 includes the electrolytic fluid 117, the at least one fluid application device 118 is configured to apply the electrolytic fluid 117 to the at least one gas turbine engine component 102, such that the electrolytic fluid 117 contacts the at least one gas turbine engine component 102, the electrode 136, and the halo 137 via the reservoir 119 of the electrolytic fluid 117.
Moreover, when the selected tank 114 includes the electrolytic fluid 117, the power source 138 is electrically connected to the electrode 136 and the halo 137.
When the selected tank 114 includes the electrolytic fluid 117, the controller 134 is further configured to control the power source 138 to provide opposite polarities to the electrode 136 and the halo 137.
Specifically, in the illustrated embodiment of FIG. 4 , for the electro-chemical etching process, the selected tank 114 includes the electrolytic fluid 117, and the controller 134 is further configured to control the power source 138 to provide the negative polarity to the electrode 136 and provide the positive polarity to the halo 137. In other words, for the electro-chemical etching process, the selected tank 114 includes the electrolytic fluid 117, the electrode 136 is the cathode, and the halo 137 is the anode.
Further, in the illustrated embodiment of FIG. 4 , for the electro-chemical plating process, the selected tank 114 includes the electrolytic fluid 117, and the controller 134 is further configured to control the power source 138 to provide the positive polarity to the electrode 136 and provide the negative polarity to the halo 137. In other words, for the electro-chemical plating process, the selected tank 114 includes the electrolytic fluid 117, the electrode 136 is the anode, and the halo 137 is the cathode.
Therefore, the system 100 including the halo 137 may be used for the electro-chemical processes, such as the electro-chemical plating process and the electro-chemical etching process. As discussed above, the at least one fluid application device 118 applying the electrolytic fluid 117 to the at least one gas turbine engine component 102 may deliver a similar, or a better result, whilst processing a lesser amount of the electrolytic fluid 117 as compared to the conventional process of immersing the at least one gas turbine engine component 102 in the conventional processing tanks including the electrolytic fluid 117 for the electro-chemical processes.
FIG. 5 illustrates a schematic front view of a system 300 for the wet treatment of the at least one gas turbine engine component 102, according to another embodiment of the present disclosure. FIG. 6A illustrates an enlarged schematic view of a portion of the system 300, according to an embodiment of the present disclosure. FIG. 6B illustrates an enlarged schematic view of another portion of the system 300, according to an embodiment of the present disclosure.
The system 300 illustrated in FIGS. 5 to 6B is substantially similar and functionally equivalent to the system 100 illustrated in FIGS. 1-4 , with common components being referred to by the same reference numerals. However, the at least one delivery valve 120 of the system 300 includes the single delivery valve 120 disposed upstream of the first fluid application device 118-1, the second fluid application device 118-2, and the third fluid application device 118-3 (instead of the three delivery valves 120 disposed upstream of the first fluid application device 118-1, the second fluid application device 118-2, and the third fluid application device 118-3, respectively, of the system 100 shown in FIG. 1 ). Further, the single delivery valve 120 is configured to selectively fluidly couple the plurality of delivery conduits 122 to the at least one fluid application device 118. For example, in the illustrated embodiment of FIG. 5 , the single delivery valve 120 is configured to selectively fluidly couple the plurality of delivery conduits 122 to the first fluid application device 118-1, the second fluid application device 118-2, and the third fluid application device 118-3 (shown in FIG. 6A). The system 300 may include the syphon 130 and the halo 137, which are not shown in FIG. 5 for the purpose of clarity.
Further, the at least one port 124 of the system 300 includes two ports 324-1, 324-2 (instead of the single port 124 of the system 100 shown in FIG. 1 ) configured to collect the corresponding fluid 116 applied by the at least one fluid application device 118.
Furthermore, the at least one recovery valve 126 of the system 300 includes the single recovery valve 126 configured to selectively fluidly couple the plurality of recovery conduits 128 to the at least one port 124 (e.g., the two ports 324-1, 324-2).
In the illustrated embodiment of FIG. 5 , the controller 134 is configured to control the single delivery valve 120, such that the selected tank 114, i.e., one of the first tank 114-1, the second tank 114-2, and the third tank 114-3 is fluidly coupled with the first fluid application device 118-1, the second fluid application device 118-2, and the third fluid application device 118-3.
The controller 134 is further configured to control the single recovery valve 126, such that the single recovery valve 126 allows the flow of the corresponding fluid 116 collected at the two ports 324-1, 324-2 to the selected tank 114, i.e., the first fluid 116-1 to the first tank 114-1, the second fluid 116-2 to the second tank 114-2, and the electrolytic fluid 117 to the third tank 114-3.
The controller 134 of system 300 may be communicably coupled to the single delivery valve 120 and the single recovery valve 126 which is not shown in FIG. 5 for the purpose of clarity.
FIG. 7 is a schematic front view of a system 500 for the wet treatment of the at least one gas turbine engine component 102, according to yet another embodiment of the present disclosure. The system 500 illustrated in FIG. 7 is substantially similar and functionally equivalent to the system 100 illustrated in FIGS. 1 to 4 , with common components being referred to by the same reference numerals. However, the at least one delivery valve 120 of the system 500 includes the plurality of delivery valves 120 corresponding to the plurality of delivery conduits 122 (instead of three delivery valves 120 corresponding to the first fluid application device 118-1, the second fluid application device 118-2, and the third fluid application device 118-3 of the system 100 of FIG. 1 ). Each delivery valve 120 from the plurality of delivery valves 120 is configured to selectively fluidly couple the corresponding delivery conduit 122 to the at least one fluid application device 118. The system 500 may include the syphon 130 and the halo 137 which are not shown in FIG. 7 for the purpose of clarity.
Further, the at least one recovery valve 126 of the system 500 includes a plurality of recovery valves 126 corresponding to the plurality of recovery conduits 128. In the illustrated embodiment of FIG. 7 , three recovery valves 126 are illustrated corresponding to three recovery conduits 128. Each recovery valve 126 from the plurality of recovery valves 126 is configured to selectively fluidly couple the corresponding recovery conduit 128 to the at least one port 124.
The controller 134 of system 500 may be communicably coupled to each of the plurality of delivery valves 120 and each of the plurality of recovery valves 126 which is not shown in FIG. 7 for the purpose of clarity.
FIG. 8 illustrates a flow chart for a method 600 for the wet treatment of the at least one gas turbine engine component 102 (shown in FIG. 1 ), according to an embodiment of the present disclosure. The method 600 will be described with reference to FIGS. 1 to 7 .
At step 602, the method 600 includes providing the chamber 104 including the base 106 and the plurality of sidewalls 108 extending from the base 106. The chamber 104 is configured to receive and at least partially enclose the at least one gas turbine engine component 102.
At step 604, the method 600 includes providing the at least one component support 112 configured to support the at least one gas turbine engine component 102 within the chamber 104.
At step 606, the method 600 includes providing the plurality of tanks 114 configured to store the corresponding plurality of fluids 116. As discussed above, the at least one tank 114 from the plurality of tanks 114 includes the electrolytic fluid 117. At step 608, the method 600 includes selectively providing the electrode 136 at least partially within the chamber 104 proximal to the at least one gas turbine engine component 102.
At step 610, the method 600 includes providing the power source 138.
At step 612, the method 600 includes providing the at least one fluid application device 118 selectively fluidly coupled to the plurality of tanks 114. The at least one fluid application device 118 is at least partially disposed within the chamber 104. The at least one fluid application device 118 is configured to apply the fluid 116 to the at least one gas turbine engine component 102.
In some embodiments, the method 600 includes selecting which of the plurality of tanks 114 to selectively couple with the at least one fluid application device 118 based on the predetermined sequence.
In some embodiments, the method 600 further includes heating and storing the corresponding fluid 116 before the at least one fluid application device 118 applies the corresponding fluid 116 stored in the selected tank 114 to the at least one gas turbine engine component 102.
In some embodiments, the method 600 further includes controlling the at least one fluid application device 118, such that the at least one fluid application device 118 applies the corresponding fluid 116 stored in the selected tank 114 to the at least one gas turbine engine component 102. In some embodiments, the method 600 further includes controlling one or more parameters of the at least one fluid application device 118. The one or more parameters include at least one of the fluid flow rate of the at least one fluid application device 118, the fluid pressure of the at least one fluid application device 118, the opening period of the at least one fluid application device 118, and the droplet size of the at least one fluid application device 118.
In some embodiments, the method 600 further includes controlling the at least one component support 112 to move the at least one gas turbine engine component 102 within the chamber 104 while the at least one fluid application device 118 applies the corresponding fluid 116 stored in the selected tank 114 to the at least one gas turbine engine component 102.
At step 614, the method 600 includes providing the at least one delivery valve 120 disposed upstream of the at least one fluid application device 118 for selectively fluidly coupling the at least one fluid application device 118 to the plurality of tanks 114.
In some embodiments, the method 600 further includes controlling the at least one delivery valve 120, such that the selected tank 114 is fluidly coupled with the at least one fluid application device 118.
In some embodiments, the method 600 further includes providing the plurality of delivery conduits 122 corresponding to the plurality of tanks 114. Each of the plurality of delivery conduits 122 fluidly couples the corresponding tank 114 to the at least one delivery valve 120.
With reference to FIG. 5 , in some embodiments, the at least one delivery valve 120 includes the single delivery valve 120. Controlling the at least one delivery valve 120 further includes controlling the single delivery valve 120 to selectively fluidly couple each of the plurality of delivery conduits 122 to the at least one fluid application device 118.
With reference to FIG. 7 , in some embodiments, the at least one delivery valve 120 includes the plurality of delivery valves 120 corresponding to the plurality of delivery conduits 122. Controlling the at least one delivery valve 120 further includes controlling each delivery valve 120 from the plurality of delivery valves 120 to selectively fluidly couple the corresponding delivery conduit 122 to the at least one fluid application device 118.
At step 616, the method 600 further includes providing the at least one port 124 disposed in the base 106 of the chamber 104. The at least one port 124 is configured to collect the fluid 116 applied by the at least one fluid application device 118.
In some embodiments, the method 600 further includes removing the corresponding fluid 116 applied by the at least one fluid application device 118 from the at least one gas turbine engine component 102. In some embodiments, the method 600 further includes transporting the corresponding fluid 116 removed from the at least one gas turbine engine component 102 to the at least one port 124.
At step 618, the method 600 further includes providing the at least one recovery valve 126 disposed downstream of the at least one port 124 for selectively fluidly coupling the at least one port 124 to the plurality of tanks 114.
In some embodiments, the method 600 further includes controlling the at least one recovery valve 126, such that the at least one recovery valve 126 allows the flow of the corresponding fluid 116 collected at the at least one port 124 to the selected tank 114.
In some embodiments, the method 600 further includes providing the plurality of recovery conduits 128 corresponding to the plurality of tanks 114. Each of the plurality of recovery conduits 128 fluidly couples the at least one recovery valve 126 to the corresponding tank 114.
With reference to FIG. 5 , in some embodiments, the at least one recovery valve 126 includes the single recovery valve 126. Controlling the at least one recovery valve 126 further includes controlling the single recovery valve 126 to selectively fluidly couple each of the plurality of recovery conduits 128 to the at least one port 124.
With reference to FIG. 7 , in some embodiments, the at least one recovery valve 126 includes the plurality of recovery valves 126 corresponding to the plurality of recovery conduits 128. Controlling the at least one recovery valve 126 further includes controlling each recovery valve 126 from the plurality of recovery valves 126 to selectively fluidly couple the corresponding recovery conduit 128 to the at least one port 124.
With reference to FIG. 3 , in some embodiments, the method 600 includes, when the selected tank 114 includes the electrolytic fluid 117, providing the electrode 136 at least partially within the chamber 104 proximal to the at least one gas turbine engine component 102, applying the electrolytic fluid 117 to the at least one gas turbine engine component 102, such that the electrolytic fluid 117 contacts the electrode 136 and the at least one gas turbine engine component 102 via the reservoir 119 of the electrolytic fluid 117, electrically connecting the power source 138 to the electrode 136 and the at least one gas turbine engine component 102, and controlling the power source 138 to provide opposite polarities to the electrode 136 and the at least one gas turbine engine component 102.
With reference to FIG. 4 , in some embodiments, the method 600 includes, when the selected tank 114 includes the electrolytic fluid 117, providing the electrode 136 at least partially within the chamber 104 proximal to the at least one gas turbine engine component 102, providing the halo 137 at least partially within the chamber 104 and at least partially surrounding the at least one gas turbine engine component 102 without contacting the at least one gas turbine engine component 102, applying the electrolytic fluid 117 to the at least one gas turbine engine component 102, such that the electrolytic fluid 117 contacts the at least one gas turbine engine component 102, the electrode 136, and the halo 137 via the reservoir 119 of the electrolytic fluid 117, electrically connecting the power source 138 to the electrode 136 and the halo 137, and controlling the power source 138 to provide opposite polarities to the electrode 136 and the halo 137.

Examples

The following examples are offered for illustrative purposes only and are not intended to limit the scope of the disclosure in any way. Indeed, various modifications of the disclosure in addition to those shown and described herein will become apparent to those skilled in the art from the foregoing description and the following examples and fall within the scope of the appended claims.
FIG. 9A shows an image of an exemplary experimental setup 800 for an application trial for an electro-chemical plating process on the left side and an image depicting a fixture 712 and a lead anode 736 on the right side. The experimental setup 800 included a rectifier device 740 functioning as a power source 738. The rectifier device 740 allowed control of the electro-chemical plating process by providing desired voltage and current.
The experimental setup 800 is substantially similar to an experimental setup as for a traditional immersion plating process. However, in the application trial for the electro-chemical plating process, a lead solution 717 was sprayed on a gas turbine engine component 702 (e.g., a bearing). Specifically, the gas turbine engine component 702 was not fully immersed in the lead solution 717.
FIG. 9B shows an image depicting the gas turbine engine component 702 before the application trial for the electro-chemical plating process on the left side and an image depicting the gas turbine engine component 702 including a lead coating 703 after performing the application trial for the electro-chemical plating process on the right side.
It was observed that the application trial provided successful electro-chemical plating of the gas turbine engine component 702. In other words, a lesser quantity of the lead solution 717 used in the application trial provided a similar lead coating 703 as the traditional immersion plating process.
It will be understood that the invention is not limited to the embodiments above described and various modifications and improvements can be made without departing from the concepts described herein. Except where mutually exclusive, any of the features may be employed separately or in combination with any other features and the disclosure extends to and includes all combinations and sub-combinations of one or more features described herein.

Claims

We claim:

1. A system for wet treating at least one gas turbine engine component, the system comprising:

a chamber comprising a base and a plurality of sidewalls extending from the base, wherein the chamber is configured to receive and at least partially enclose the at least one gas turbine engine component;

at least one component support configured to support the at least one gas turbine engine component within the chamber;

a plurality of tanks configured to store a corresponding plurality of fluids, wherein at least one tank from the plurality of tanks comprises an electrolytic fluid;

an electrode disposed at least partially within the chamber proximal to the at least one gas turbine engine component;

a power source;

at least one fluid application device selectively fluidly coupled to the plurality of tanks, wherein the at least one fluid application device is at least partially disposed within the chamber, and wherein the at least one fluid application device is configured to apply the fluid to the at least one gas turbine engine component;

at least one delivery valve disposed upstream of the at least one fluid application device for selectively fluidly coupling the at least one fluid application device to the plurality of tanks;

at least one port disposed in the base of the chamber, wherein the at least one port is configured to collect the fluid applied by the at least one fluid application device;

at least one recovery valve disposed downstream of the at least one port for selectively fluidly coupling the at least one port to the plurality of tanks; and

a controller communicably coupled to each of the at least one fluid application device, the at least one delivery valve, the at least one recovery valve, and the power source.

2. The system of claim 1, wherein the controller is configured to:

select which of the plurality of tanks to selectively couple with the at least one fluid application device based on a predetermined sequence;

control the at least one delivery valve, such that the selected tank is fluidly coupled with the at least one fluid application device;

control the at least one fluid application device, such that the at least one fluid application device applies the corresponding fluid stored in the selected tank to the at least one gas turbine engine component; and

control the at least one recovery valve, such that the at least one recovery valve allows a flow of the corresponding fluid collected at the at least one port to the selected tank.

3. The system of claim 2, wherein when the selected tank comprises the electrolytic fluid:

the electrode is disposed at least partially within the chamber proximal to the at least one gas turbine engine component;

the at least one fluid application device is configured to apply the electrolytic fluid to the at least one gas turbine engine component, such that the electrolytic fluid contacts the electrode and the at least one gas turbine engine component via a reservoir of the electrolytic fluid;

the power source is electrically connected to the electrode and the at least one gas turbine engine component; and

the controller is further configured to control the power source to provide opposite polarities to the electrode and the at least one gas turbine engine component.

4. The system of claim 2, further comprising a halo selectively disposed at least partially within the chamber, wherein when the selected tank comprises the electrolytic fluid:

the halo is disposed at least partially within the chamber and at least partially surrounds the at least one gas turbine engine component without contacting the at least one gas turbine engine component;

the at least one fluid application device is configured to apply the electrolytic fluid to the at least one gas turbine engine component, such that the electrolytic fluid contacts the at least one gas turbine engine component, the electrode, and the halo via a reservoir of the electrolytic fluid;

the power source is electrically connected to the electrode and the halo; and

the controller is further configured to control the power source to provide opposite polarities to the electrode and the halo.

5. The system of claim 1, further comprising:

a plurality of delivery conduits corresponding to the plurality of tanks, wherein each of the plurality of delivery conduits fluidly couples the corresponding tank to the at least one delivery valve; and

a plurality of recovery conduits corresponding to the plurality of tanks, wherein each of the plurality of recovery conduits fluidly couples the at least one recovery valve to the corresponding tank.

6. The system of claim 5, wherein:

the at least one delivery valve comprises a single delivery valve configured to selectively fluidly couple the plurality of delivery conduits to the at least one fluid application device; and

the at least one recovery valve comprises a single recovery valve configured to selectively fluidly couple the plurality of recovery conduits to the at least one port.

7. The system of claim 5, wherein:

the at least one delivery valve comprises a plurality of delivery valves corresponding to the plurality of delivery conduits, and wherein each delivery valve from the plurality of delivery valves is configured to selectively fluidly couple the corresponding delivery conduit to the at least one fluid application device; and

the at least one recovery valve comprises a plurality of recovery valves corresponding to the plurality of recovery conduits, and wherein each recovery valve from the plurality of recovery valves is configured to selectively fluidly couple the corresponding recovery conduit to the at least one port.

8. The system of claim 1, wherein the controller is communicably coupled to the at least one component support, and wherein the controller is further configured to control the at least one component support to move the at least one gas turbine engine component within the chamber while the at least one fluid application device applies the corresponding fluid stored in the selected tank to the at least one gas turbine engine component.

9. The system of claim 1, wherein the base is inclined towards the at least one port.

10. The system of claim 1, wherein the controller is further configured to control one or more parameters of the at least one fluid application device, and wherein the one or more parameters comprise at least one of a fluid flow rate of the at least one fluid application device, a fluid pressure of the at least one fluid application device, an opening period of the at least one fluid application device, and a droplet size of the at least one fluid application device.

11. The system of claim 1, wherein the at least one fluid application device comprises a plurality of fluid application devices, and wherein the plurality of fluid application devices follows a profile of the at least one gas turbine engine component.

12. The system of claim 1, further comprising a heating device disposed upstream of the at least one fluid application device, wherein the heating device is configured to heat and store the corresponding fluid before the at least one fluid application device applies the corresponding fluid stored in the selected tank to the at least one gas turbine engine component.

13. The system of claim 1, further comprising at least one syphon conduit configured to remove the corresponding fluid applied by the at least one fluid application device to the at least one gas turbine engine component, and wherein the at least one syphon conduit is further configured to transport the corresponding fluid removed from the at least one gas turbine engine component to the at least one port.

14. The system of claim 1, wherein the power source comprises a rectifier.

15. A method for wet treating at least one gas turbine engine component, the method comprising the steps of:

providing a chamber comprising a base and a plurality of sidewalls extending from the base, wherein the chamber is configured to receive and at least partially enclose the at least one gas turbine engine component;

providing at least one component support configured to support the at least one gas turbine engine component within the chamber;

providing a plurality of tanks configured to store a corresponding plurality of fluids, wherein at least one tank from the plurality of tanks comprises an electrolytic fluid;

providing an electrode at least partially within the chamber proximal to the at least one gas turbine engine component;

providing a power source;

providing at least one fluid application device selectively fluidly coupled to the plurality of tanks, wherein the at least one fluid application device is at least partially disposed within the chamber, and wherein the at least one fluid application device is configured to apply a fluid to the at least one gas turbine engine component;

providing at least one delivery valve disposed upstream of the at least one fluid application device for selectively fluidly coupling the at least one fluid application device to the plurality of tanks;

providing at least one port disposed in the base of the chamber, wherein the at least one port is configured to collect the fluid applied by the at least one fluid application device; and

providing at least one recovery valve disposed downstream of the at least one port for selectively fluidly coupling the at least one port to the plurality of tanks.

16. The method of claim 15, further comprising:

selecting which of the plurality of tanks to selectively couple with the at least one fluid application device based on a predetermined sequence;

controlling the at least one delivery valve, such that the selected tank is fluidly coupled with the at least one fluid application device;

controlling the at least one fluid application device, such that the at least one fluid application device applies the corresponding fluid stored in the selected tank to the at least one gas turbine engine component; and

controlling the at least one recovery valve, such that the at least one recovery valve allows a flow of the corresponding fluid collected at the at least one port to the selected tank.

17. The method of claim 16, further comprising, when the selected tank comprises the electrolytic fluid:

providing the electrode at least partially within the chamber proximal to the at least one gas turbine engine component;

applying the electrolytic fluid to the at least one gas turbine engine component, such that the electrolytic fluid contacts the electrode and the at least one gas turbine engine component via a reservoir of the electrolytic fluid;

electrically connecting the power source to the electrode and the at least one gas turbine engine component; and

controlling the power source to provide opposite polarities to the electrode and the at least one gas turbine engine component.

18. The method of claim 16, further comprising, when the selected tank comprises the electrolytic fluid:

providing a halo at least partially within the chamber and at least partially surrounding the at least one gas turbine engine component without contacting the at least one gas turbine engine component;

applying the electrolytic fluid to the at least one gas turbine engine component, such that the electrolytic fluid contacts the at least one gas turbine engine component, the electrode, and the halo via a reservoir of the electrolytic fluid;

electrically connecting the power source to the electrode and the halo; and

controlling the power source to provide opposite polarities to the electrode and the halo.

19. The method of claim 15, further comprising:

providing a plurality of delivery conduits corresponding to the plurality of tanks, wherein each of the plurality of delivery conduits fluidly couples the corresponding tank to the at least one delivery valve; and

providing a plurality of recovery conduits corresponding to the plurality of tanks, wherein each of the plurality of recovery conduits fluidly couples the at least one recovery valve to the corresponding tank.

20. The method of claim 15, further comprising controlling the at least one component support to move the at least one gas turbine engine component within the chamber while the at least one fluid application device applies the corresponding fluid stored in the selected tank to the at least one gas turbine engine component.