초록 ▼

Although the method and apparatus of the present invention can be utilized to apply either a uniform or a nonuniform covering of material over many different workpieces, the apparatus (20) is advantageously utilized to apply a thermal barrier covering (64) to an airfoil (22) which is used in a turbi

Although the method and apparatus of the present invention can be utilized to apply either a uniform or a nonuniform covering of material over many different workpieces, the apparatus (20) is advantageously utilized to apply a thermal barrier covering (64) to an airfoil (22) which is used in a turbine engine. The airfoil is held by a gripper assembly (86) while a spray gun (24) is effective to apply the covering over the airfoil. When a portion of the covering has been applied, a sensor (28) is utilized to detect the thickness of the covering. A control apparatus (32) compares the thickness of the covering of material which has been applied with the desired thickness and is subsequently effective to regulate the operation of the spray gun to adaptively apply a covering of a desired thickness with an accuracy of at least plus or minus 0.0015 inches (1.5 mils) despite unanticipated process variations.

대표청구항 ▼

A method of forming an airfoil, said method comprising the steps of providing a base having a configuration which is different than the configuration of the airfoil, applying material to the base to form the airfoil, said step of applying material to the base to form the airfoil including the steps

A method of forming an airfoil, said method comprising the steps of providing a base having a configuration which is different than the configuration of the airfoil, applying material to the base to form the airfoil, said step of applying material to the base to form the airfoil including the steps of operating a spray means to direct a flow of material toward the base to form on the base a body of sprayed material extending at least part way around the base and having an exterior surface area with a configuration corresponding to the configuration of at least a portion of the airfoil, and removing the base from the body of sprayed material to provide an airfoil having a cavity with a configuration corresponding to the configuration of the base.