Patent Description:
Coatings are extensively used in turbine engines in order to protect various surfaces of the turbine engine when the turbine engine is operating. One example of a coating is a thermal barrier coating. Coatings may often degrade during service of the turbine engine by spallation, damage, or the like. Typically, a thermal barrier coating is restored at regularly scheduled maintenance intervals by disassembling the turbine engine so that a restorative thermal barrier coating can be applied.

This maintenance of the engine results in significant down time and expense. The thermal barrier coating may not wear and degrade in the same manner for each individual aircraft or system that includes an engine with a thermal barrier coating. Thus, a thermal barrier coating may need to be restored at intervals that do not coincide with the regularly scheduled maintenance schedule of the engine or aircraft. The end result is either reduced engine performance resulting from a coating in use that needs to be restored, or unnecessary down time spent restoring a coating that does not need to be restored. <CIT> relates to a spraying-tool head which as a distribution plate fitted to an adapter and, screwed onto the distribution plate, a nozzle plate equipped with spray nozzles. <CIT> relates to a double coating of an outer diameter and an apparatus for manufacturing steel pipe having an epoxy resin coating layer which coats an inner diameter and an outer diameter at once. <CIT> discloses a spraying device for inner wall coating of a ladle.

In one embodiment, a coating system comprises: a support fixture sized to be partially inserted into one or more openings of a component; and a plurality of spray nozzle segment devices, wherein each spray nozzle segment device comprises a housing configured to receive a slurry, each spray nozzle segment device configured to be disposed radially outward of a central axis of the component and wherein each housing is shaped such that the respective spray nozzle segment device extends circumferentially about at least part of the central axis of the component, each housing comprising plural delivery nozzles configured to spray the slurry onto a surface of the component,wherein each spray nozzle segment device is configured to be operably coupled with the support fixture such that the support fixture maintains a position of the spray nozzle segment device within the component when the support fixture is partially inserted into the one or more openings of the component, wherein the slurry comprises a first fluid and a slurry of solid particles and a second fluid, wherein the slurry is configured to be formed inside the housing, wherein the first fluid is configured to promote evaporation of the second fluid as droplets of the slurry traverse from the housing toward one or more surfaces of the component, and wherein each spray nozzle segment device is configured to be operably coupled with each other spray nozzle segment device in order to form a rail system extending circumferentially about at least part of the central axis of the component.

In one embodiment, a method comprises: maintaining a position of a plurality of spray nozzle segment devices inside a component with a support fixture, each spray nozzle segment device comprising a housing configured to receive a slurry, each spray nozzle segment device configured to be disposed radially outward of a central axis of the component and wherein the housing is shaped such that the spray nozzle segment device extends circumferentially about at least part of the central axis of the component, the housing comprising plural delivery nozzles configured to spray the slurry onto a surface of the component, the support fixture sized to be partially inserted into one or more openings of the component, wherein each spray nozzle segment device is configured to be operably coupled with the support fixture such that the support fixture maintains a position of the spray nozzle segment device within the component when the support fixture is partially inserted into the one or more openings of the component, and wherein each spray nozzle segment device is configured to be operably coupled with each other spray nozzle segment device in order to form a rail system extending circumferentially about at least part of the central axis of the component; and spraying the slurry onto the surface of the component as a coating on the component; wherein the slurry comprises a first fluid and a slurry of solid particles and a second fluid, wherein the slurry is configured to be formed inside the housing, wherein the first fluid is configured to promote evaporation of the second fluid as droplets of the slurry traverse from the housing toward one or more surfaces of the component.

The present inventive subject matter will be better understood from reading the following description of non-limiting embodiments, with reference to the attached drawings, wherein below:.

One or more embodiments of the inventive subject matter described herein relate to coating system that effectively improves the life of a barrier coating. The coating system includes one or more spray nozzle segment devices that are disposed inside a component, such as a turbine engine. A support fixture extends between a first end outside of the component and a second end inside the component. The second end of the support fixture is operably coupled with the spray nozzle segment device in order to maintain a position of the device inside the component. The device includes a housing that receives a fluid-and-ceramic slurry mixture, and plural delivery nozzles that spray the mixture onto the component as a coating on the component while the position of the device is maintained.

Two or more devices are disposed inside the component and operably coupled with each other in order to form a rail system extending circumferentially about at least a part of a central axis of the component. The rail system including plural spray nozzle segment devices spray the mixture as a restorative coating onto plural surfaces substantially simultaneously while the position of each of the devices is maintained by one or more support fixtures. At least one technical effect of the subject matter described herein includes improving the reduction of time to spray or deposit the mixture as the coating onto the component or reducing the time for which the turbine engine is out of service.

The coating system provides a restorative coating onto the component without a locomotion device or locomotion control system to move the spray nozzle segment device over the surfaces of the component to spray the mixture onto the component as the coating. Additionally, the coating system provides a restorative coating onto the component without any moving components inside the turbine engine while the mixture is sprayed onto the interior surfaces of the turbine engine. At least one technical effect of the subject matter described herein includes improved reduction of a risk of lost, faulty, damaged, or the like, of moving components inside the turbine engine.

<FIG> illustrates a cut-away cross-sectional schematic view of a coating system <NUM> in accordance with one embodiment. <FIG> illustrates a magnified view of the coating system <NUM> of <FIG>. The coating system <NUM> includes a component <NUM> that is to be coated on one or more surfaces of the component <NUM> with a fluid-and-ceramic slurry mixture. The component <NUM> includes a central axis <NUM> and an inner surface <NUM> and an outer surface <NUM> that extend circumferentially around the central axis <NUM>. The inner and outer surfaces <NUM>, <NUM> are radially disposed outward of the central axis <NUM> of the component <NUM> in a radial direction <NUM>. For example, the inner surface <NUM> is disposed at a radial position between the central axis <NUM> and the outer surface <NUM> in the radial direction <NUM>. In the illustrated embodiment, the inner and outer surfaces <NUM>, <NUM> are only partially illustrated extending circumferentially around only a part of the central axis <NUM>.

In the illustrated embodiment, the component <NUM> represents a turbine engine, but optionally may be another type of machine or equipment. The component also includes an outer housing or casing <NUM> that circumferentially extends around and encloses a rotatable shaft (not shown). The casing <NUM> includes several ports or openings <NUM>, <NUM> that extend through the casing <NUM> and provide access to the interior of the casing <NUM>. These ports or openings <NUM>, <NUM> may be stage one nozzle ports, stage two nozzle ports, borescope ports, igniter ports, or the like. For example, the openings <NUM>, <NUM> provide access to the interior of the component <NUM> without significantly disassembling the component <NUM> (e.g., the turbine engine).

The coating system <NUM> also includes one or more spray nozzle segment devices <NUM> that are disposed radially outward of the central axis <NUM> between the inner and outer surfaces <NUM>, <NUM>. Each of the devices <NUM> are shaped such that each device <NUM> extends circumferentially about at least a part of the center axis <NUM>. For example, each device <NUM> is shaped such that when the plural devices <NUM> are operably coupled with each other to form a circular rail system <NUM>, the rail system <NUM> has a cross-sectional shape that is concentric with and common to the cross-sectional shape of the inner and outer surfaces <NUM>, <NUM> about the center axis <NUM>. In the illustrated embodiment, each of the plural devices <NUM> are disposed substantially centered between the inner and outer surfaces <NUM>, <NUM>. Optionally, one or more of the devices <NUM> may be disposed at a position that is closer to the inner surface <NUM> than the outer surface <NUM>, closer to the outer surface <NUM> than the inner surface <NUM>, or at any alternative radial position.

The spray nozzle segment devices <NUM> are sized in order to be inserted in the component through one or more of the ports or openings <NUM>, <NUM>. For example, the devices <NUM> may be inserted into the interior of the component <NUM> without disassembling the component <NUM> (e.g., the turbine engine). Additionally, the devices <NUM> are inserted into the turbine engine in order to spray a fluid-and-ceramic slurry mixture onto one or more surfaces of the component <NUM>. For example, the slurry may be sprayed from and deposited onto a thermal barrier coating of one or more surfaces of the component <NUM>.

As illustrated, the system <NUM> includes plural devices <NUM> that are operably coupled with each other and extend completely circumferentially about the center axis <NUM>. Optionally, the system <NUM> may include any number of devices <NUM> that are operably coupled with each other device <NUM>. Not according to the invention, the coupled devices <NUM> may not extend completely circumferentially about the center axis <NUM>. For example, the system <NUM> may include any number of devices <NUM> that may extend circumferentially about only a part of the central axis <NUM>.

The plural devices <NUM> may be operably coupled to each other at each end of the devices <NUM> by a foldable or hinged joint by a fastener, a magnet, or the like. For example, two or more devices <NUM> may be operably coupled to each other by a hinged joint such that the two devices <NUM> are coupled together outside the component, are transferred through one of the ports or openings <NUM>, <NUM>, and are unhinged or unfolded such that the two or more devices <NUM> form a partial substantially circular rail system <NUM> that extends at least partially about the central axis <NUM>.

Each of the devices <NUM> includes a housing <NUM> having a hollow chamber (illustrated in <FIG>) disposed therethrough. The housing <NUM> of each device <NUM> also includes plural delivery nozzles <NUM>. The delivery nozzles <NUM> operate to direct a coating of the fluid-and-ceramic slurry mixture onto one or more surfaces of the component <NUM>. The housing <NUM> of the devices <NUM> will be described in more detail below.

The coating system <NUM> also includes one or more support fixtures <NUM>. The support fixture <NUM> is sized to be partially inserted into one or more of the ports or openings <NUM>, <NUM>. The support fixture <NUM> includes a first end <NUM> that is disposed outside of the component <NUM> and a second end <NUM> that is disposed inside the component <NUM>. For example, the support fixture <NUM> includes a body that extends between the first end <NUM> outside of the component <NUM> and the second end <NUM> inside the component, wherein the body substantially fills the port or opening <NUM>, <NUM> in order to be press-fit into the opening <NUM>, <NUM>. Optionally, the body of the support fixture <NUM> may include any alternative locking mechanism, shape, size, or the like, such that the position of the support fixture <NUM> is maintained inside the port or opening <NUM>, <NUM>.

The second end <NUM> of the support fixture <NUM> is operably coupled with one or more of the devices <NUM> in order to maintain a position of the devices <NUM> inside the component <NUM> between the inner and outer surfaces <NUM>, <NUM>. For example, the second end <NUM> may be detachably coupled with the device <NUM> by a fastener, magnet, clamp, or the like. Optionally, the second end <NUM> may not be detachably coupled with the device <NUM>. In the illustrated embodiment, a single support fixture <NUM> is operably coupled with the plural spray nozzle segment devices <NUM> that are operably coupled with each other device <NUM> to form the rail system <NUM>. Optionally, the system <NUM> may include any number of support fixtures <NUM> disposed at any location about the central axis <NUM> of the component <NUM>.

The support fixture <NUM> maintains a position of the one or more devices <NUM> inside the component <NUM>. Additionally, the support fixture <NUM> maintains a position of the devices <NUM> while the devices <NUM> spray the restorative coating on the component <NUM>. For example, the delivery nozzles <NUM> of each device <NUM> direct the coating of the fluid-and-ceramic slurry mixture onto one or more surfaces of the component <NUM> while the position of the device <NUM> inside of the component <NUM> is maintained and does not move. The support fixture <NUM> illustrated in <FIG> and <FIG> illustrates one embodiment of a support fixture <NUM>. Optionally, the support fixture <NUM> may have any alternative shape, size, or the like, that allows the support fixture to maintain a position of the spray nozzle segment devices <NUM> inside the component <NUM>.

The spray nozzle segment device <NUM> is operably and fluidly coupled with a tube <NUM>. The tube <NUM> may be a guide tube or a coaxial tube that includes two or more individual tubes disposed inside the tube <NUM>. The tube <NUM> extends between the device <NUM> inside the component <NUM> through one or more of the ports or openings <NUM>, <NUM> to a reservoir <NUM> that is disposed outside the component <NUM>. In the illustrated embodiment, the tube <NUM> fluidly couples a single device <NUM> with the reservoir <NUM>. Additionally or alternatively, the system <NUM> may include one or more tubes <NUM> that may fluidly couple two or more different devices <NUM> with the reservoir <NUM>. For example, each device <NUM> may be fluidly coupled with the reservoir <NUM> by a tube <NUM>. Optionally, the system <NUM> may include plural tubes <NUM> that may provide fluid from the reservoir <NUM> via one or more valves <NUM>.

The spray nozzle segment device <NUM> receives fluid from the reservoir <NUM> via one or more pumps (not shown) to provide the fluid-and-ceramic slurry mixture into the device <NUM>. The fluid may be a gas, and the slurry mixture may include water and the ceramic particles such as any solid particles that function to form a coating or that deliver an additive to the component <NUM>. The fluid of the reservoir <NUM> is selected to promote evaporation of the fluid in droplets formed by the spray nozzle segment device <NUM> as the droplets traverse through the air from the device <NUM> before impacting one or more surfaces of the component <NUM>. In this manner, the fluid is either eliminated from the droplet that impacts the component <NUM> or the amount of fluid remaining in the droplet impacting the component <NUM> is substantially reduced. The fluid may be a liquid in one or more embodiments, but alternatively may include a gas.

Similarly, the temperature of the fluid-and-ceramic slurry mixture in the system <NUM> can be increased, either by a heating element <NUM>, or by a different device or method such that when the fluid is discharged from the spray nozzle segment device <NUM> again the amount of fluid remaining in the droplet impacting the component <NUM> is substantially reduced. Such increase in temperature, or heating, can occur at the reservoir <NUM>, in conduits or the tube <NUM> conveying the slurry to the device <NUM>, or within the spray nozzle segment device <NUM>. In one example, both the temperature of the slurry is increased within the system <NUM> and the fluid is selected to promote evaporation.

In one or more embodiments, the reservoir <NUM> may also be designed to reduce the amount of gas from evaporated fluid that is conveyed to the spray nozzle segment device <NUM> relative to one or more other reservoirs (not shown). Specifically, the reservoir <NUM> may have an outlet adjacent to the reservoir <NUM> or can be cooled to prevent gas from evaporated fluid from flowing from the reservoir <NUM>. This ensures that the slurry mixture of fluid and ceramic particles can be created and ensures a minimal amount of fluid evaporates in the system <NUM> prior to discharging the slurry mixture from the spray nozzle segment device <NUM>.

In one or more embodiments, the system <NUM> may include a slurry mixture reservoir and a different, separate gas reservoir (not shown). For example, the slurry mixture reservoir may include a slurry of fluid and ceramic materials. The fluid may be alcohol, water, or the like. The gas reservoir may include a different, first fluid that may be a gas such as air, nitrogen, argon, or the like. The first fluid (e.g., air) may be pumped by a pump (not shown), and the slurry may be pumped the same or a unique pump (not shown) into the tube <NUM> in order to direct the first fluid and the slurry of fluid and ceramic particles into the device <NUM> to form the slurry inside the device <NUM>. When discharged, the first fluid and the slurry combine to form two-phase droplets. As the droplets traverse toward the surface of the component <NUM> the liquid in the slurry evaporates leaving only the ceramic particles to provide a uniform coating on the one or more surfaces of the component <NUM>.

In one or more embodiments, the first fluid (e.g., a gas) and the slurry including the ceramic particles mixed with the second fluid liquid (e.g., water) may be mixed inside the reservoir <NUM> in order to create the fluid-and-ceramic slurry mixture in order to generate the droplets at a location outside of the component. The droplets may be received into the device <NUM> and then deposited from the device <NUM> in order to coat the component <NUM>. Additionally or alternatively, the slurry mixture may be mixed inside one or more of the devices <NUM>. For example, the devices <NUM> may receive the first fluid (e.g., the gas) from the reservoir <NUM> via a first tube <NUM>, and may receive the second fluid (e.g., the slurry of ceramic particles in the liquid) via a different, second tube <NUM>. The devices <NUM> may atomize the slurry mixture and generate the droplets inside each device <NUM>.

The system <NUM> also includes a control system <NUM>. The control system <NUM> can be used to control operation of the component <NUM> during spraying of the coating using one or more of the spray nozzle segment devices <NUM> described herein. The control system <NUM> includes an equipment controller that represents hardware circuitry that includes and/or is connected with one or more processors (e.g., one or more microprocessors, field programmable gate arrays, integrated circuits, or the like).

The control system <NUM> also includes a spray controller <NUM> that controls an amount (e.g., volume) of the slurry that is provided to the device <NUM>, a pressure of the slurry that is provided to the device <NUM>, a flow rate at which the slurry is provided to the device <NUM>, a temporal duration at which the slurry is provided to the device <NUM>, a time at which the slurry is provided to the device <NUM>, or the like. Additionally, each spray nozzle segment device <NUM> may be fluidly coupled with the reservoir <NUM> by separate tubes <NUM>. The spray controller <NUM> may control an amount (e.g., volume) of the slurry that is provided to each of the devices <NUM>, a pressure of the slurry that is provided to each of the devices <NUM>, a flow rate at which the slurry is provided to each of the devices <NUM>, a temporal duration at which the slurry is provided to each of the devices <NUM>, a time at which the slurry is provided to each of the devices <NUM>, or the like. For example, the spray controller <NUM> may operate autonomously based on a program or software of the control system <NUM>.

Additionally, the spray controller <NUM> may also control operation of the one or move valves <NUM> of the reservoir <NUM> in order to control an amount (e.g., volume) of the slurry that is provided to each of the devices <NUM>, a pressure of the slurry that is provided to the devices <NUM>, a flow rate at which the slurry is provided to the devices <NUM>, a temporal duration at which the slurry is provided to the devices <NUM>, a time at which the slurry is provided to the devices <NUM>, or the like. Additionally or alternatively, the spray controller <NUM> may control a delivery sequence or delivery schedule of the slurry to each of the spray nozzle segment devices <NUM> by controlling the valves <NUM>. For example, the spray controller <NUM> may control a first valve to deliver the slurry to a first device at a first time, and may control the first valve or a different, second valve to deliver the slurry to a different, second device at a second time that is after the first time. Optionally, the spray controller <NUM> may control operation of the valves <NUM> in any alternative ways to control the delivery of the slurry from the reservoir <NUM> to each of the spray nozzle segment devices <NUM>.

In one or more embodiments, the spray controller <NUM> may also control an amount of the first fluid (e.g., the gas) and/or an amount of the slurry of fluid and ceramic particles that is provided to the reservoir <NUM> from one or more additional reservoirs (not shown). Additionally, the spray controller <NUM> may control a pressure of each of the components of the slurry mixture that is provided to the reservoir <NUM> and/or to the devices <NUM>, a flow rate at which of each of the components is provided to the reservoir <NUM> and/or to the devices <NUM>, a temporal duration at which each of the components is provided to the reservoir <NUM> and/or the devices, a time at which each of the components of the slurry mixture is provided to the reservoir <NUM> and/or the devices <NUM>, or the like. Optionally, the spray controller <NUM> may also control an amount of the first fluid that is provided to one or more of the devices <NUM> and an amount of the slurry of fluid and ceramic particles that are provided to one or more of the devices <NUM>. For example, the first fluid and the slurry may be mixed inside the devices <NUM> in order to atomize the slurry mixture and generate the droplets inside the devices <NUM>.

In one or more embodiments, the system <NUM> may include plural spray controllers <NUM>. Each of the spray controllers <NUM> may be operably coupled with one or more reservoirs in order to control the slurry that is provided to a single device <NUM>. For example, each spray controller <NUM> may control the delivery of the slurry to one or more devices <NUM>. The spray controllers <NUM> may control an amount (e.g., volume) of the slurry that is provided to each device <NUM>, a pressure of the slurry that is provided to each device <NUM>, a flow rate at which the slurry is provided to each device <NUM>, a temporal duration at which the slurry is provided to each device <NUM>, a time at which the slurry is provided to the device <NUM>, or the like.

The spray controller <NUM> represents hardware circuitry that includes and/or is connected with one or more processors, and one or more pumps, valves, or the like, of the system <NUM>, for controlling the flow of materials to the device <NUM> for spraying a restorative coating onto the interior of the component <NUM>. The spray controller <NUM> can generate signals communicated to the valves <NUM>, pumps, or the like, via one or more wired and/or wireless connections to control delivery of the slurry to the devices <NUM>.

<FIG> illustrates a schematic view of the spray nozzle segment device <NUM> in accordance with one embodiment. <FIG> illustrates a cross-sectional view of the spray nozzle segment device <NUM> in accordance with one embodiment. <FIG> will be described in detail together.

The housing <NUM> of the spray nozzle segment device <NUM> has a substantially circular cross-sectional shape and is elongated between a first end <NUM> and a second end <NUM>. In the illustrated embodiment, the housing <NUM> is substantially tubular in shape and includes a curve or arc between the first and second ends <NUM>, <NUM>. For example, the housing <NUM> of each device <NUM> is shaped such that the device <NUM> extends partially circumferentially about or around a part of the central axis <NUM> (of <FIG>). Additionally, the housing <NUM> is shaped such that the coupled devices <NUM> form or create a circular rail system <NUM> that is substantially concentric with the inner and outer surfaces <NUM>, <NUM> of the component <NUM> about or around the central axis <NUM>.

The housing <NUM> includes an inlet <NUM> that receives the tube <NUM> that extends into the component <NUM>. The inlet <NUM> fluidly couples the tube <NUM> with a conduit <NUM> of the housing <NUM>. The slurry mixture <NUM> is received into the device <NUM> through the inlet <NUM>. In the illustrated embodiment, the inlet <NUM> is disposed at the first end <NUM> of the housing <NUM>. Additionally or alternatively, the inlet <NUM> may be disposed at any location and/or surface of the housing <NUM>. For example, the inlet <NUM> may be disposed at an outer surface <NUM> of the housing <NUM> at any location between the first and second end <NUM>, <NUM>.

In one or more embodiments, the housing <NUM> may have two or more inlets. For example, a first inlet may be fluidly coupled with a first tube and receive a first fluid (e.g., a gas such as air), and the second inlet may be fluidly coupled with a second tube and receive the slurry of fluid and ceramic particles. For example, the slurry mixture <NUM> may be formed inside the housing <NUM>.

The conduit <NUM> of the housing <NUM> is a hollow chamber that extends through the housing <NUM> from a conduit inlet <NUM> to a conduit outlet <NUM>. The conduit <NUM> has a conduit diameter that narrows between the conduit inlet <NUM> to the conduit outlet <NUM> such that the conduit <NUM> has a diameter at the conduit outlet <NUM> that is less than a diameter at the conduit inlet <NUM>. The narrowing diameter of the conduit <NUM> causes the fluid therein to increase in speed through the conduit <NUM>.

The spray nozzle segment device <NUM> is fluidly and operably coupled with a second spray nozzle segment device <NUM>. For example, the second end <NUM> of the device <NUM> illustrated in <FIG> is operably coupled with a first end of a second device (not shown). Additionally, the conduit outlet <NUM> of the device <NUM> illustrated in <FIG> may be fluidly coupled with a conduit inlet of a second device (not shown) such that the slurry mixture <NUM> may flow from the device <NUM> to the second device <NUM>. Optionally, the two devices <NUM> may be operably coupled with each other but may not be fluidly coupled with each other. For example, the first device may not include a conduit outlet <NUM> and the second device may include a conduit inlet that receives the slurry mixture through a second tube <NUM>.

The delivery nozzles <NUM> of the device <NUM> are fluidly coupled with the conduit <NUM> at a location between the conduit inlet <NUM> and the conduit outlet <NUM>. The delivery nozzles <NUM> direct the slurry mixture <NUM> towards the surfaces of the component <NUM> being coated. For example, the conduit <NUM> and the housing <NUM> are shaped to control a flow rate of the slurry mixture <NUM> between the conduit inlet <NUM> and the delivery nozzles <NUM> and/or the outlet <NUM>. In the illustrated embodiment, the delivery nozzles <NUM> are disposed at a location downstream from the inlet <NUM> at a location between the first and second ends <NUM>, <NUM>. Additionally, the delivery nozzles <NUM> are spaced apart from each other in substantially uniform distances and directions. For example, the delivery nozzles <NUM> are disposed around the outer surface <NUM> of the housing <NUM> in order to direct the slurry mixture <NUM> out of the housing <NUM> and onto the component <NUM> in different directions. Optionally, the delivery nozzles <NUM> may be disposed closer to or further apart from each other, have a random and/or patterned configuration, or any combination therein.

The spray nozzle segment device <NUM> is held in a position inside the component <NUM> by the support fixture <NUM>. In the illustrated embodiment, the second end <NUM> of the support fixture <NUM> is operably coupled with the device <NUM> at a location closer to the second end <NUM> of the device <NUM> than the first end <NUM> of the device <NUM>. Optionally, the support fixture <NUM> may be operably coupled with the device <NUM> at any location of the device <NUM> between the first and second ends <NUM>, <NUM>. Additionally or alternatively, two or more support fixtures <NUM> may be operably coupled with the device <NUM> in order to maintain a position of the device <NUM> inside the component <NUM> while the delivery nozzles <NUM> spray the slurry mixture <NUM> onto the component <NUM> as the coating on the component <NUM>.

<FIG> illustrates a partial cross-sectional view of the coating system <NUM> in accordance with one embodiment. The spray nozzle segment device <NUM> is disposed inside the component <NUM> between the inner and outer surfaces <NUM>, <NUM> of the component in a radial direction (e.g., the radial direction <NUM> of <FIG>). Additionally, the spray nozzle segment device <NUM> is disposed between a first interior surface <NUM> and a second interior surface <NUM> in an axial direction. In the illustrated embodiment, the device <NUM> is disposed substantially centered within the component <NUM>.

The delivery nozzles <NUM> of the device <NUM> direct or spray the slurry mixture <NUM> onto the inner surface <NUM>, the outer surface <NUM>, the first interior surface <NUM>, and the second interior surface <NUM>. The delivery nozzles <NUM> spray the slurry mixture <NUM> to apply a restorative coating as a uniform coating on each surface of the component <NUM>. For example, the device <NUM> provides <NUM> degrees of sprayed coating onto the component. Optionally, the device <NUM> may include delivery nozzles <NUM> having an alternative configuration such that the delivery nozzles <NUM> spray the slurry mixture <NUM> only one surface of the component <NUM> and not onto the other surfaces of the component <NUM>. For example, the delivery nozzles <NUM> may apply the coating as a non-uniform coating on each surface of the component <NUM>.

In one or more embodiments, the delivery nozzles <NUM> of each device <NUM> may be configured to deliver the slurry onto one or more surfaces, joints, supports, or the like. For example, a first spray nozzle segment device <NUM> may be disposed inside the component at a position proximate to a joint between two or more surfaces, and a second spray nozzle segment device <NUM> may be disposed inside the component at a position proximate a substantially planar surface. The delivery nozzles <NUM> of the first device may have a first configuration in order to provide a substantially uniform coating onto the two surfaces forming the joint. The delivery nozzles <NUM> of the second device may have a different, second configuration in order to provide a substantially uniform coating onto the substantially planar surface.

<FIG> illustrates a schematic view of a rail system <NUM> of a coating system <NUM> in accordance with one embodiment. The rail system <NUM> includes plural spray nozzle devices <NUM> that are operably coupled with each other in a circular configuration about or around the central axis <NUM>. In the illustrated embodiment, the rail system <NUM> includes nine devices 104A-I. Each of the devices 104A-I have substantially a common shape and size. Alternatively, one or more of the devices <NUM> may have a unique shape or size relative to the other devices <NUM>. The nine devices 104A-I are operably coupled with each other such that a first end <NUM> of each device is operably coupled with a second end <NUM> of another device <NUM> to form or create the circular rail system <NUM>.

The position of each of the devices <NUM> is maintained with four support fixtures 132A-D that extend into the component and are operably coupled with four different devices <NUM>. In the illustrated embodiment, each support fixture <NUM> is disposed substantially <NUM> degrees apart from a different support fixture <NUM> about or around the central axis <NUM>. Additionally or alternatively, the support fixtures <NUM> may be disposed at any other random or patterned position about or around the central axis <NUM> relative to each other support fixture <NUM>.

The coating system <NUM> includes three tubes 618A-C that deliver the slurry mixture to three different devices <NUM>. For example, a first tube 618A provides the slurry mixture to the device 104A, a second tube 618B provides the slurry mixture to the device 104D, and a third tube <NUM> provides the slurry mixture to the device <NUM>. Optionally, the system <NUM> may include nine tubes to provide the slurry mixture to each of the nine devices, may include a single tube to provide the slurry mixture to one device, or any combination therein.

In the illustrated embodiment, the devices 104A, 104B, and 104C are also fluidly coupled with each other. For example, the slurry mixture that is provided by the first tube 618A to the device 104A flows through the devices 104A, 104B, 104C in order to the delivery nozzles of each of the devices 104A, 104B, 104C to spray the slurry mixture onto the surfaces of the component that are disposed proximate to the devices 104A, 104B, 104C. Additionally, each of the devices 104A, 104B, 104C may be shaped and/or sized in order to control a flow rate of the slurry mixture through each of the devices 104A, 104B, 104C that are fluidly coupled with each other. Similarly, the devices 104D, 104E, and 104F are fluidly coupled with each other. The slurry mixture that is provided by the second tube 618B to the device 104D flows through the devices 104D, 104E, and 104F. The devices <NUM>, <NUM>, and 104I are also fluidly coupled with each other such that the slurry mixture provided by the third tube 618C to the device <NUM> flows through the devices <NUM>, <NUM>, and 104I. Additionally or alternatively, the rail system <NUM> may include any number of devices that are fluidly coupled with each other and operably coupled with each other in any alternative configuration. For example, each of the devices 104A-104I may be fluidly coupled with each other such that each of the devices 104A-104I receives the slurry mixture provided by one or more tubes <NUM>.

<FIG> illustrates a flow chart <NUM> of a method of coating a surface utilizing a spray nozzle segment device. At <NUM>, a coating application where a component needs to be coated is determined. At <NUM>, a determination is made how many surfaces, what areas, how large of an area, or the like, of the component needs to be coated. Based on the determination at <NUM>, one or more spray nozzle segment devices are provided and may be inserted into the component via one or more openings at <NUM>. Two or more of the spray nozzle segment devices are operably coupled with each other, may be fluidly coupled with each other.

At <NUM> a position of the one or more spray nozzle segment devices disposed inside the component is maintained with one or more support fixtures. The support fixtures extend between a first end disposed outside of the component and a second end disposed inside the component. The spray nozzle segment devices are disposed radially outward of a central axis of the component. For example, the devices may be operably coupled with each in order to form a rail system extending circumferentially about or around at least a part of the central axis of the component between an inner surface and an outer surface of the component along a radial direction.

Each of the spray nozzle segment devices also includes plural delivery nozzles. The devices receive a fluid-and-ceramic slurry mixture into the device from a reservoir disposed outside the component via a tube, conduit, coaxial conduit, or the like. In one embodiment, each of the spray nozzle segment devices receives a slurry mixture that includes a slurry of a fluid and ceramic particles combined with a first fluid (e.g., air). The first fluid is used to create droplets from the slurry mixture. Optionally, each device may receive the slurry of the fluid and ceramic particles via one tube or conduit, and the first fluid via a second, different tube or conduit. Optionally, one or more devices receives the fluid-and-ceramic slurry mixture and the slurry mixture flows from one device to each other device fluidly coupled together. Optionally, each of the devices may be fluidly coupled with each other. The devices may receive the slurry of the fluid and ceramic particles via one tube or conduit and the slurry may flow from one device to each other device. One or more of the devices may also receive the first fluid (e.g., the gas) via a second tube or conduit in order to atomize the slurry mixture in order to create droplets from the slurry mixture inside each device. Optionally, each device may receive the slurry mixture, the first fluid, and/or the slurry by an alternative means or method.

At <NUM>, the delivery nozzles spray the slurry mixture onto the component as a coating on the component while the position of the spray nozzle segment device is maintained. For example, while the slurry mixture is sprayed onto the component, the device does not or substantially does not move.

Optionally, the coating system includes a spray controller that is disposed outside the component and is operably coupled with the reservoir. The spray controller may control one or more of an amount of the slurry mixture that is provided to one or more devices, a pressure of the slurry mixture that is provided to one or more devices, a flow rate at which the slurry mixture is provided to one or more devices, a temporal duration at which the slurry mixture is provided to one or more devices, a time at which the slurry mixture is provided to one or more devices, or the like.

In a first example of the method, a turbine engine on a wing of an airplane has a thermal barrier coating that is to be restored. Alcohol is chosen as the fluid to be mixed with the ceramic particles to form the slurry, because alcohol is a fluid that promotes evaporation. After the devices discharge the spray as part of a slurry from the delivery nozzles, droplets that include the fluid are formed. As the droplets traverse through the air, the fluid evaporates substantially reducing the amount of fluid in the droplet before the droplet impacts the surface of the turbine to form the coating.

In a second example of the method when a turbine blade requires a coating, water is the fluid selected to be mixed with the ceramic particles to form the slurry and does not promote evaporation of the fluid. In this example, the temperature of the two-phase droplets is increased compared to the temperature of the two-phase droplets without auxiliary heating of the droplets. Auxiliary heating of the droplets can include, but is not limited to, increasing the temperature of the water flowing to the inlet of the device or increasing the temperature of the water within the device as a result of an additional heat source within the device, or the like. By increasing the temperature of the fluid, in this example water above the ambient temperature, the likelihood of evaporation of the water in the droplets is increased. Thus, the selected temperature of the fluid promotes evaporation. In this embodiment, the amount of water that evaporates from the droplets substantially reduces the amount of water in the droplets upon impact compared to the amount of water discharged from the devices.

Optionally, the housing of the spray nozzle segment device is sized to be inserted into the one or more openings of the component.

Optionally, the spray nozzle segment device is fluidly coupled with a reservoir disposed outside the component with one or more valves.

The coating system also includes plural spray nozzle segment devices. Each of the spray nozzle segment devices are configured to be operably coupled with each other spray nozzle segment device in order to form a rail system extending circumferentially about at least part of the central axis of the component.

Optionally, each of the plural spray nozzle segment devices are fluidly coupled with each other nozzle segment device. Each of the plural spray nozzle segment devices are configured to receive the slurry.

Optionally, each of the plural spray nozzle segment devices are sized in order to control a flow rate of the slurry through each of the plural nozzle segment devices.

Optionally, the coating system also includes plural support fixtures. The plural support fixtures are configured to maintain a position of each of the plural spray nozzle segment devices inside the component.

Optionally, each of the plural spray nozzle segment devices are fluidly coupled with a reservoir disposed outside the component with one or more valves.

Optionally, the coating system also includes a spray controller. The spray controller is configured to control operation of the one or more valves in order to control one or more of an amount of the slurry provided to each of the spray nozzle segment devices, a pressure of the slurry provided to each of the spray nozzle segment devices, a flow rate of the slurry provided to each of the spray nozzle segment devices, a temporal duration at which the slurry is provided to each of the spray nozzle segment devices, or a time at which the slurry is provided to each of the spray nozzle segment devices.

Optionally, the coating system also includes a spray controller configured to control one or more of an amount of the slurry provided to the spray nozzle segment device, a pressure of the slurry provided to the spray nozzle segment device, a flow rate at which the slurry is provided to the spray nozzle segment device, a temporal duration at which the slurry is provided to the spray nozzle segment device, or a time at which the slurry is provided to the spray nozzle segment device.

Optionally, the coating system also includes a spray controller configured to control one or more of an amount of the slurry provided to each of the one or more delivery nozzles, a pressure of the slurry provided to each of the one or more delivery nozzles, a flow rate at which the slurry is provided to each of the one or more delivery nozzles, a temporal duration at which the slurry is provided to each of the one or more delivery nozzles, or a time at which the slurry is provided to each of the one or more delivery nozzles.

Optionally, the slurry includes a first fluid and a slurry of ceramic particles and a second fluid. The slurry is configured to be formed inside the housing.

The first fluid is configured to promote evaporation of the second fluid as droplets of the slurry traverse from the housing toward one or more surfaces of the component.

Optionally, the spray nozzle segment device is configured to be inserted into a turbine engine to spray the slurry onto one or more surfaces of the turbine engine without disassembling the turbine engine.

Optionally, the one or more delivery nozzles are configured to spray the slurry onto one or more surfaces of the component to apply the coating as a uniform coating.

Optionally, the spray nozzle segment device is configured to be inserted into a turbine engine to spray the slurry onto one or more surfaces of an interior of the turbine engine.

Optionally, the coating is configured to be deposited on a thermal barrier coating of the component.

Optionally, the housing is shaped to control a flow rate of the slurry between an inlet of the housing and the delivery nozzles of the housing.

The method also includes disposed plural spray nozzle segment devices radially outward of the central axis of the component. Each of the spray nozzle segment devices are configured to be operably coupled with each other spray nozzle segment device in order to form a rail system extending circumferentially about at least part of the central axis of the component.

Optionally, the method also includes fluidly coupling each of the plural spray nozzle segment devices with each other spray nozzle segment device. Each of the plural spray nozzle segment devices are configured to receive the slurry.

Optionally, each of the plural spray nozzle segment devices are sized in order to control a flow rate of the slurry through each of the plural spray nozzle segment devices.

Optionally, the method also includes controlling operation of the one or more valves in order to control one or more of an amount of the slurry provided to each of the spray nozzle segment devices, a pressure of the slurry provided to each of the spray nozzle segment devices, a flow rate at which the slurry is provided to each of the spray nozzle segment devices, a temporal duration at which the slurry is provided to each of the spray nozzle segment devices, or a time at which the slurry is provided to each of the spray nozzle segment devices.

Optionally, the method also includes controlling one or more of an amount of the slurry provided to the spray nozzle segment device, a pressure of the slurry provided to the spray nozzle segment device, a flow rate at which the slurry is provided to the spray nozzle segment device, a temporal duration at which the slurry is provided to the spray nozzle segment device, or a time at which the slurry is provided to the spray nozzle segment device with a spray controller operably coupled with the spray nozzle segment device.

Optionally, the method also includes controlling one or more of an amount of the slurry provided to each of the one or more delivery nozzles, a pressure of the slurry provided to each of the one or more delivery nozzles, a flow rate at which the slurry is provided to each of the one or more delivery nozzles, a temporal duration at which the slurry is provided to each of the one or more delivery nozzles, or a time at which the slurry is provided to each of the one or more delivery nozzles with a spray controller operably coupled with the spray nozzle segment device.

Optionally, the method also includes inserting the spray nozzle segment device into a turbine engine to spray the slurry onto one or more surfaces of the turbine engine without disassembling the turbine engine.

Optionally, the housing is shaped to control a flow rate at which the slurry flows between an inlet of the housing and the delivery nozzles of the housing.

In one embodiment of the subject matter described herein, a coating system includes a component to be coated. The component includes an inner surface and an outer surface extending circumferentially around at least part of a central axis of the component. One or more support fixtures are sized to be partially inserted into one or more openings of the component. Each support fixture extends between a first end disposed outside of the component and a second end disposed inside the component. The coating system also includes plural spray nozzle segment devices disposed radially outward of the central axis of the component between the inner and outer surfaces of the component. Each of the spray nozzle segment devices comprises a housing configured to receive a slurry. Each housing comprising plural delivery nozzles. The spray nozzle segment devices shaped to extend circumferentially about at least part of the central axis of the component. The spray nozzle segment devices are configured to be operably coupled with the one or more support fixtures inside the component such that the support fixtures maintain a position of each of the spray nozzle segment devices between the inner surface and the outer surface of the component. The delivery nozzles are configured to spray the mixture onto the component as a coating on the component while the position of each of the spray nozzle segment devices is maintained.

Claim 1:
A coating system (<NUM>) comprising:
a support fixture (<NUM>) sized to be partially inserted into one or more openings (<NUM>, <NUM>) of a component (<NUM>); and
a plurality of spray nozzle segment devices (<NUM>), wherein each spray nozzle segment device (<NUM>) comprises a housing (<NUM>) configured to receive a slurry, each spray nozzle segment device (<NUM>) configured to be disposed radially outward of a central axis (<NUM>) of the component (<NUM>) and wherein each housing (<NUM>) is shaped such that the respective spray nozzle segment device (<NUM>) extends circumferentially about at least part of the central axis (<NUM>) of the component (<NUM>), each housing (<NUM>) comprising plural delivery nozzles (<NUM>) configured to spray the slurry onto a surface (<NUM>, <NUM>, <NUM>, <NUM>) of the component (<NUM>),
wherein each spray nozzle segment device (<NUM>) is configured to be operably coupled with the support fixture (<NUM>) such that the support fixture (<NUM>) maintains a position of the spray nozzle segment device (<NUM>) within the component (<NUM>) when the support fixture (<NUM>) is partially inserted into the one or more openings (<NUM>, <NUM>) of the component (<NUM>),
wherein the slurry comprises a first fluid and a slurry of solid particles and a second fluid, wherein the slurry is configured to be formed inside the housing (<NUM>), wherein the first fluid is configured to promote evaporation of the second fluid as droplets of the slurry traverse from the housing (<NUM>) toward one or more surfaces of the component (<NUM>), and
wherein each spray nozzle segment device (<NUM>) is configured to be operably coupled with each other spray nozzle segment device (<NUM>) in order to form a rail system (<NUM>) extending circumferentially about at least part of the central axis (<NUM>) of the component (<NUM>).