System and Method for Wet Treatment of a Component

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.

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.

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.

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.

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.

illustrates a schematic front view of a systemfor wet treatment of at least one gas turbine engine component, according to an embodiment of the present disclosure. In the illustrated embodiment of, the at least one gas turbine engine componentis a single gas turbine engine component. However, in some other embodiments, the at least one gas turbine engine componentmay include a plurality of gas turbine engine components. In some embodiments, the at least one gas turbine engine componentof the gas turbine engine may be a bladed disk drum or a fan blade.

The systemincludes a chamber. Specifically, the systemincludes a housingdefining the chamber. The chamberincludes a baseand a plurality of sidewallsextending from the base. The chamberis configured to receive and at least partially enclose the at least one gas turbine engine component. In other words, the housingof the chamberreceives and at least partially encloses the at least one gas turbine engine component.

The systemis manufactured using materials suitable for the manufacture of wet processing systems, and for a chemistry being applied. In some examples, the chambermay be made of a metallic material, a polymeric material, a ceramic material, or a combination thereof. In some other examples, the chambermay be made of, but not limited to, stainless steel, quartz, or alumina. In some other examples, the systemmay include several chambers (e.g., the chamber), for enabling different wet treatment processes on the at least one gas turbine engine component. Further, the chambers may be manufactured of different materials that may allow different types of the wet treatment processes.

The systemfurther includes at least one component supportconfigured to support the at least one gas turbine engine componentwithin the chamber. In the illustrated embodiment of, the systemincludes one component supportconfigured to support the gas turbine engine component. However, any number or type of the at least one component supportmay be used to support the corresponding gas turbine engine componentbased on desired application attributes. For example, the at least one component supportmay include at least one of a jig, a rotatable gas turbine engine component, a support fixture, a hanging support, or the like.

The systemfurther includes a plurality of tanksconfigured to store a corresponding plurality of fluids. At least one tank from the plurality of tanksincludes an electrolytic fluid. In other words, at least one of the plurality of fluidsincludes the electrolytic fluid. In some cases, the plurality of fluidsmay be collectively or individually referred to hereinafter as “the fluid”.