Rolls-Royce Corporation

Virginia Tech Intellectual Properties Inc

Virginia Polytechnic Institute and State University

Turbine Surface Technologies Limited

Rolls-Royce North American Technologies Inc.

Raymond John Sinatra

Michael Cybulsky

Taylor K Blair

Gary R Pickrell

Romesh Batra

Ann Bolcavage

Matthew R Gold

Kang N Lee

Melissa Hughes

Roy Peter McIntyre

Mark Hudson

Jesse S Daugherty

Marvin Alexander

An example system includes at least one acoustic sensor configured to generate at least one time-dependent acoustic data signal indicative of an acoustic signal generated by a thermal spray system performing a process possessing a plurality of process attributes, and a computing device including an acoustic data signal processing module configured to receive the at least one time-dependent acoustic data signal, and transform the at least one time-dependent acoustic data signal to a frequency-domain spectrum, wherein each process attribute of the plurality of process attributes is associated with at least one respective frequency band, and a correlation module configured to determine a process attribute of the plurality of process attributes by identifying at least one characteristic of the frequency-domain spectrum.

Thermal spray diagnostics

A characteristic of a component having an engineered internal space can be analyzed by recording acoustic signals produced by fluid flow through the internal space at controlled flow rates, and determining one or more acoustic frequencies and acoustic intensities that are indicative of the characteristic of the component. A state and/or a source of the component can be predicted based on the results of such analysis.

Analysis of component having engineered internal space for fluid flow

An example system includes at least one acoustic sensor configured to generate at least one acoustic data signal indicative of an acoustic signal generated by a thermal spray system comprising a flowstream, a computing device, and an acoustic data signal processing module operable by the computing device to determine an ignition attribute of the thermal spray system by analyzing at least a pre-ignition window of the acoustic data signal received by the computing device.

Diagnosis of thermal spray gun ignition

The disclosure relates to a high temperature mechanical system, such as a gas turbine engine, including a first coating deposited on a first substrate and a second coating deposited on a second substrate. The first coating includes a first bond layer, a second bond layer, and a first ceramic outer layer, wherein the second bond layer is between the first bond layer and first ceramic outer layer. The second coating includes a third bond layer deposited on the substrate and a second ceramic outer layer deposited on the third bond layer. The second coating is configured to abrade the first coating, e.g., during operation of the high temperature mechanical system.

Abradable ceramic coatings and coating systems

An article may include an array of features formed in a substrate and may be coated with a coating layer. The array of features may mitigate stress experienced by the coated article. In particular, the array of features may reduce or limit crack propagation at the interface between the substrate and the coating layer. In some examples, the article is an airfoil that includes a tip that defines an edge. An array of features is formed on the surface of the tip, where the array of features is proximate to the edge, and the array of features does not intersect the edge. The airfoil includes a coating layer formed on the surface of the tip and the array of features.

Substrate features for mitigating stress

An article may include an array of features formed in a substrate and may be coated by a thermal barrier coating (TBC). The array of features may mitigate thermal stress experienced by the coated article. In particular, the array of features may reduce or limit crack propagation at or above the interface of a thermally insulative layer and a bond coat in the TBC. In some embodiments, the array may be formed proximate to and substantially aligned with cooling holes formed in the substrate. In other embodiments, an article may include a first array of features formed in a first location of a substrate and a second array of features formed in a second location of a substrate. The first and second locations may be determined or selected based on a prediction of thermal stresses that the substrate will experience at the first and second locations during use.

An abradable coating may include a rare earth silicate. The abradable coating may be deposited over a substrate, an environmental barrier coating, or a thermal barrier coating. The abradable coating may be deposited on a gas turbine blade track or a gas turbine blade shroud to form a seal between the gas turbine blade track or gas turbine blade shroud and a gas turbine blade. The abradable coating may also include a plurality of layers, such as alternating first and second layers including, respectively, a rare earth silicate and stabilized zirconia or stabilized hafnia.

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Indianapolis, IN, United States of America

Raymond John Sinatra