Predetermining the thickness of a coating

Abstract

A method for predetermining a thickness of a coating which is to be arranged on a substrate is provided. A spray spot is arranged on a surface of the substrate or a test substrate. The volume of the spray spot is determined, and based on the determined volume, the thickness of a layer which is to be applied is worked out. An arrangement for predetermining the thickness of a coating is further provided.

Claims

1. A method for spraying a coating material onto a substrate, the method comprising: spraying, by a spray gun connected to a gas container and a gas heater, a spot of coating material onto only a portion of the substrate, in a fixed time span, wherein, during the spraying, the spray gun moves at a speed, v, relative to a surface of the substrate, along parallel tracks having a track offset, p, that guides the spray gun during the spraying; detecting, by a device, a volume of the spot applied to the portion of the substrate; calculating, by a controller coupled to the spray gun and the device, a layer thickness of a complete coating that is to be later applied to the substrate by the spray gun, based on the volume of the spot as detected by the device, wherein the layer thickness is determined by the equation:
h.sub.layer=1/(v*p)*ΔV.sub.spot/Δt where h.sub.layer is the layer thickness, v is the speed, p is the track offset defining a spacing between the parallel tracks, ΔV.sub.spot is the volume of the spot, and Δt is the fixed time span; and in response to the calculating the layer thickness by the control device, applying, by the spray gun, the complete coating of coating material to the substrate at the layer thickness, wherein, during the applying the complete coating of coating material at the layer thickness, the spray gun moves at the speed, v, along parallel tracks having the track offset, p.

2. The method as claimed in claim 1, wherein the substrate is a test substrate.

3. The method as claimed in claim 1, wherein the substrate is a gas turbine component.

4. The method as claimed in claim 1, wherein the volume of the applied spray spot is determined by tactile profilometry.

5. The method as claimed in claim 1, wherein the volume of the applied spray spot is determined by optical profilometry.

6. The method as claimed in claim 1, wherein the volume of the applied spray spot is determined by an optical 3-D scanning technique.

7. The method as claimed in claim 6, wherein the optical 3-D scanning technique performed is a structured light scan.

Description

BRIEF DESCRIPTION

(1) Some of the embodiments will be described in detail, with reference to the following figures, wherein like designations denote like members, wherein:

(2) FIG. 1 shows an arrangement for carrying out a method for predetermining the thickness of a coating, in accordance with embodiments of the present invention;

(3) FIG. 2 is a schematic depiction of a path followed by the device for arranging a complete coating during coating, relative to the substrate, in accordance with embodiments of the present invention;

(4) FIG. 3 is a photographic depiction of a spray spot of a coating material being sprayed, in accordance with embodiments of the present invention;

(5) FIG. 4 is a flow chart of a method for predetermining the thickness of a coating, in accordance with embodiments of the present invention;

DETAILED DESCRIPTION

(6) One embodiment of an arrangement 1 according to embodiments of the invention is depicted in FIG. 1. The arrangement 1 comprises a device 2 for arranging a coating, which device is in the form of a spray gun 2. The spray gun is ideally used in a cold spray process for spraying particles in a gas stream onto the surface of a substrate 3. To that end, the spray gun 2 is connected to a high-pressure gas container 4 for providing high-pressure gas, a gas heater 5 for heating the gas, a material container 6 and a heater 7 for a powdered material 8.

(7) The device 2 for arranging a coating may be of a different design, depending on the type of application. Other embodiments of the device 2 for arranging a coating are possible depending on the form of the device, for example a plasma nozzle in combination with a liquid or powder injector for suspension plasma spraying, or a flame tube for flame spraying, in particular powder flame spraying.

(8) The spray gun 2 is designed such that, during application of the coating material 8, it is able to move relative to the surface of the substrate that is to be coated. In that context, the spray gun 2 is guided in parallel tracks over the surface of the substrate to be coated, as depicted in FIG. 2.

(9) The substrate 3 is an iron-based or nickel-based metallic alloy, ideally a metallic superalloy, such as are used for temperature-resistant components of gas turbines. The coating material is ideally a pulverized ceramic material, such as is typically used for thermal barrier coatings. It is however also possible to apply a metallic alloy as the coating, for example of the type MCrAlY.

(10) The spray gun 2 is connected to a control device 9. The control device 9 is designed to calculate the thickness of a spray spot 10 applied to the surface of the substrate 3, on the basis of the determined volume. FIG. 3 depicts the spray spot 10 applied to the surface of the substrate 3, during application. To that end, the control device 8 is further connected to a device 11 for determining the volume of the spray spot 10 applied by the device for arranging a coating 2. The device 11 can be a profilometer which operates either tactilely and examines the spray spot 10 by touch, for example using a diamond needle, or operates optically, for example using confocal techniques or laser profilometry or white light profilometry are determined contactlessly by optical profilometry. Alternatively, the device 11 can also be a device for three-dimensional scanning, which is in particular a structured light sensor. The control device 9 is designed both to output control commands to the device 11 and also to receive and further process data from the device 11.

(11) In a method according to the embodiment shown in FIG. 4, a first step S1 involves preparing a substrate 3 with a surface. The substrate 3 is preferably a flat metallic plate. A second step S2 involves providing a device 2 for arranging a coating on the substrate. Depending on the desired form of the coating, the device 2 provided is a spray gun as in FIG. 1 or alternatively a flame tube or a plasma nozzle. A third step S3 involves arranging a coating material, by applying the material from the device 2 on the surface of the substrate. This produces a spray spot of the deposited material on the surface of the substrate. Step S3 is carried out in a fixed time span.

(12) A fourth step S4 involves determining the volume of an applied spray spot applied in a fixed time span, for example by tactile profilometry, wherein the three-dimensional structure of the applied spray spot is detected using a device 11, in particular a profilometer through examining by touch using a needle, and the identified structure is used to determine the volume of the applied spray spot. Alternatively, the volume of the applied spray spot can be determined contactlessly by optical profilometry. In another alternative embodiment, the volume of the sprayed spray spot can be determined in the method according to embodiments of the invention by an optical 3-D scanning technique. The 3-D scanning technique performed can be a structured light scan using blue or white light.

(13) A fifth step S5 involves predetermining the thickness of a coating that is to be applied, on the basis of the determined volume of the applied spray spot. In that context, the value of the determined volume is plugged into the equation
h.sub.layer=1/(v*p)*ΔV.sub.spot/Δt
where h.sub.layer is the thickness of the complete coating, v is the speed of the device for arranging a coating, p is the track offset, ΔV.sub.spot is the determined volume of the applied spray spot, and Δt is the time span fixed for the arranging. In that context, the values of the determined volume are transmitted to the control device which carries out the requisite calculation operation.

(14) Although the present invention has been disclosed in the form of preferred embodiments and variations thereon, it will be understood that numerous additional modifications and variations could be made thereto without departing from the scope of the invention.

(15) For the sake of clarity, it is to be understood that the use of “a” or “an” throughout this application does not exclude a plurality, and “comprising” does not exclude other steps or elements.