APPARATUS, SYSTEM, AND METHOD FOR IN-SITU APPLICATION OF ENGINEERING COATING

Description

CROSS REFERENCE TO RELATED APPLICATIONS

This specification is based upon and claims the benefit of priority from United Kingdom patent application number GB 2418133.1 filed on December 11th 2024, the entire contents of which is incorporated herein by reference.

BACKGROUND

1.Technical Field

This disclosure relates generally to an apparatus, a system, and a method for in-situ application of an engineering coating to one or more components.

2. Description of the Related Art

Components of various machines may be typically coated to protect them during use, for example, to minimise wear and generally improve their safe and useful life. Gas turbine engine components, particularly those located in gas paths of such engines, may be required to withstand extreme temperatures (or high thermal loads) and abrasive contacts for prolonged periods of time and hence maintaining their integrity may be critical. Such components may be typically manufactured from specialised materials, for example, titanium alloys, which may be protected by an engineering coating. The engineering coating may help such components to survive higher operating temperatures and environmental stresses, increases component durability, and improves engine reliability. The engineering coating may be typically formed of a ceramic material and may be deposited on an environmental protective bond coat. The engineering coating may be a thermal barrier coating or an environmental barrier coating.

Under service conditions, the gas turbine engine components may be susceptible to various modes of damage, including erosion, oxidation and corrosion from exposure to the gaseous products of combustion, foreign object damage, and attack from environmental contaminants. The source of environmental contaminants may be ambient air, which may be drawn in by the gas turbine engine for cooling and combustion. The type of environmental contaminants in ambient air may vary from location to location but may be of a concern to aircraft as their purpose is to move from location to location. These environmental contaminants may be in addition to the corrosive and oxidative contaminants that result from the combustion of fuel.

Some of these contaminants may result in the loss of engineering coating over the life of the components, leaving a thin portion of the engineering coating, or completely removing a portion of the engineering coating and leaving the underlying component exposed to the operational conditions and potentially damaging such component.

Hence, an apparatus, and/or system, and/or method for applying the engineering coating may be useful. However, in the known art for applying the engineering coating, when one or more components are determined to be worn and/or damaged, the machine (e.g., a gas turbine engine) may require disassembly so that the one or more components may be accessed, and the engineering coating may be applied thereto. This conventional method of application of the engineering coating may be a relatively time consuming and costly procedure. Moreover, this may also reduce the throughput and efficiency of the machine as the machine needs to be disassembled for application of the engineering coating to the one or more components.

SUMMARY

In a first aspect, an apparatus for in-situ application of an engineering coating to one or more components is provided. The apparatus includes a head section adapted to selectively apply the engineering coating to the one or more components. The head section includes an applicator end and a coupling end opposite to the applicator end. Further, the apparatus includes a body section coupled to the head section at the coupling end and adapted to actuate the head section. The body section includes a first stage actuator adapted to actuate the head section to swivel about a first axis, and a second stage actuator adapted to actuate the head section and the first stage actuator together to rotate about a second axis. The second axis is orthogonal to the first axis. Further, the apparatus includes one or more gas channels provided along the body section to the head section.

The apparatus of the present disclosure may allow repairing of patches on the one or more components of a machine (e.g., a gas turbine engine). The one or more components may be hot-end components such as turbine blades and combustor tiles of the gas turbine engine. In applications where the one or more components are parts of the gas turbine engine, the apparatus of the present disclosure may allow repairing of patches on the one or more components while the gas turbine engine is on-wing to minimise disruption of operation. In other words, for application of the engineering coating to the one or more components, there may be no need for disassembly of the gas turbine engine, thereby preventing any loss of operational efficiency of the gas turbine engine. Moreover, the repairing of patches on the one or more components may be done in a time efficient and cost-efficient manner.

The apparatus of the present disclosure may be brought in proximity to the gas turbine engine, or the apparatus may be at least partially inserted within the gas turbine engine for accessing and repairing of the one or more components by applying the engineering coating thereto.

Further, the apparatus of the present disclosure while applying the engineering coating to the one or more components may not impart any residual stress or microstructural changes in the one or more components. This may be due to selective swivelling movement of the head section about the first axis, and the combined rotary movement of the head section and the first stage actuator about the second axis. Such swivelling movement of the head section and the combined rotary movement of the head section and the first stage actuator may allow the applicator end to be directed away from the one or more components during initial ignition and set-up so as to avoid create a poorly adhered coating patch. Moreover, such swivelling movement of the head section and the combined rotary movement of the head section and the first stage actuator may allow the apparatus to apply the engineering coating of desirable dimensions and shapes depending on the target area on the one or more components. Furthermore, such swivelling movement of the head section and the combined rotary movement of the head section and the first stage actuator may prevent the one or more components from overheating while the engineering coating is applied thereto.

The term “engineering coating” according to the present disclosure may be defined as a coating that may alter the surface properties of the substrate or component to which the engineering coating may be applied. The engineering coating may be a thermal barrier coating (or TBC) i.e. a thermally insulating material that is applied to the substrate that is typically exposed to elevated temperatures, or an environmental barrier coating (or EBC) i.e. a barrier coating that is applied to the substrate that is typically exposed to environmental stresses such as icing and erosion.

In some embodiments, the head section includes a nozzle head, and a nozzle arm coupled to the nozzle head. The nozzle head and nozzle arm may allow for precise control over the movement and positioning of at least one nozzle that may be included with the head section, thereby enabling accurate coating deposition. Further, the nozzle arm may allow for a wide range of motion, giving the apparatus of the present disclosure the ability to position the nozzle head at various angles or positions.

In some embodiments, the first stage actuator includes a first stage housing, and a first stage motor housed within the first stage housing. The first stage motor has a first stage motor shaft. Further, the first stage actuator includes a lead screw coupled to the first stage motor shaft and adapted to be rotated by the first stage motor through the first stage motor shaft. The first stage actuator further includes a lead screw nut rotationally coupled to the lead screw. Further, the first stage actuator includes a pair of side levers. Each of the pair of side levers is coupled to the lead screw nut at one end and coupled to the nozzle arm at another end. A rotation of the lead screw by the first stage motor shaft pushes the lead screw nut, and the lead screw nut subsequently pushes the pair of side levers to actuate a swivel motion of the nozzle arm about the first axis. The first stage actuator may utilize a lead screw mechanism to control the swivel motion of the nozzle arm. The lead screw mechanism may provide fine control over the nozzle arm's movement. Further, since the lead screw converts rotational motion into linear motion with minimal backlash, the apparatus of the present disclosure may achieve precise positioning of the nozzle arm, which may be crucial for application of the engineering coating to the one or more components. Further, the lead screw may effectively transmit high torque with relatively low effort and may thereby allow the first stage actuator to generate significant force with a relatively small first stage motor. This may allow for a compact structure of the apparatus.

In some embodiments, the swivel motion of the nozzle arm ranges between a first position and a second position in both planes of motion respectively. The ability to swivel in two planes of motion may provide enhanced manoeuvrability, allowing the at least one nozzle to cover a wider area of the one or more components to which the engineering coating may be applied. Further, with independent control of movement in the two planes of motion, the at least one nozzle may direct the engineering coating in the exact desired direction, leading to more efficient application of the engineering coating to the one or more components.

In some embodiments, the first position of the nozzle arm corresponds to the nozzle head being parallel to the second axis. The nozzle arm may allow for a wide range of motion, giving the apparatus of the present disclosure the ability to position the nozzle head at various angles or positions. As an example, the nozzle head may be positioned in a home position when igniting and stabilizing the flame. The term “home position” according to the present disclosure may be defined as an initial position of the nozzle head with the nozzle head facing away from the one or more components to be coated with the engineering coating.

In some embodiments, the second position of the nozzle arm corresponds to the nozzle head being inclined with respect to the second axis. The nozzle arm may allow for a wide range of motion, giving the apparatus of the present disclosure the ability to position the nozzle head at various angles or positions. As an example, the nozzle head may be positioned in a working position when applying engineering coating to the one or more components. The term “working position” according to the present disclosure may be defined as a position of the nozzle head with the nozzle head facing towards the one or more components to be coated with the engineering coating.

In some embodiments, the second stage actuator includes a second stage housing, and a second stage motor housed within the second stage housing. The second stage motor is adapted to actuate a rotational motion of the first stage actuator and the head section together about the second axis. The second stage motor by rotating the first stage actuator and the head section about the second axis may allow the apparatus, and/or the first stage actuator and/or the head section to gain additional degrees of freedom. The inclusion of additional motor into the apparatus may allow for more complex movements and finer control, enabling the head section to be positioned with greater flexibility in multiple directions.

In some embodiments, the one or more gas channels includes a first channel for a ceramic powder carried within an inert gas, a second channel for a fuel gas in liquid or gaseous form, and a third channel for a cooling gas. The apparatus of the present disclosure may have one or more gas channels to receive and carry the gases required for forming the engineering coating towards the head section.

In some embodiments, the one or more components is a gas turbine engine component. The gas turbine engine components may be hot-end components such as turbine blades and combustor tiles of the gas turbine engine. However, the one or more components may be any other component of the gas turbine engine or any other machine.

In a second aspect, there is provided a system for in-situ application of an engineering coating to one or more components. The system includes an apparatus that further includes a head section adapted to selectively apply the engineering coating to the one or more components. The head section includes an applicator end and a coupling end opposite to the applicator end. The apparatus further includes a body section coupled to the head section at the coupling end and adapted to actuate the head section. The body section includes a first stage actuator adapted to actuate the head section to swivel about a first axis, and a second stage actuator adapted to actuate the head section and the first stage actuator together to rotate about a second axis. The second axis is orthogonal to the first axis. Further, the apparatus includes one or more gas channels provided along the body section to the head section. Further, the system includes a deployment device for deploying the apparatus near the one or more components, and a source of engineering coating material coupled to the deployment device for supplying the engineering coating material to the apparatus.

The system of the present disclosure may allow repairing of patches on the one or more components of a machine (e.g., a gas turbine engine) by using the deployment device. The one or more components may be hot-end components such as turbine blades and combustor tiles. In applications where the one or more components are parts of the gas turbine engine, the system of the present disclosure may allow repairing of patches on the one or more components while the gas turbine engine is on-wing to minimise disruption of operation. In other words, for application of the engineering coating to the one or more components, there may be no need for disassembly of the gas turbine engine, thereby preventing any loss of operational efficiency of the gas turbine engine. Moreover, the repairing of patches on the one or more components by the system of the present disclosure may be done in a time efficient and cost-efficient manner.

The system of the present disclosure may bring the apparatus in proximity to the gas turbine engine, or the apparatus may be at least partially inserted within the gas turbine engine for accessing and repairing of the one or more components by applying the engineering coating thereto. Specifically, the deployment device may provide forward movement to the apparatus to effectively apply the engineering coating to the one or more components. The deployment device may provide retract movement to the apparatus to avoid clashing against the backwall of a combustor. The forward and retract movement of the apparatus may prevent the one or more components from overheating while the engineering coating is applied to the one or more components.

Moreover, in the system of the present disclosure, selective swivelling movement of the head section and the combined rotary movement of the head section and the first stage actuator may allow the applicator end to be directed away from the one or more components during initial ignition and set-up so as to avoid create a poorly adhered coating patch. Further, such swivelling movement of the head section and the combined rotary movement of the head section and the first stage actuator may allow the system to apply the engineering coating of desirable dimensions and shapes depending on the target area on the one or more components. Furthermore, such swivelling movement of the head section and the combined rotary movement of the head section and the first stage actuator may prevent the one or more components from overheating while the engineering coating is applied thereto.

In some embodiments, the head section comprises a nozzle head, and a nozzle arm coupled to the nozzle head. The nozzle head and nozzle arm may allow for precise control over the movement and positioning of at least one nozzle that may be included with the head section, thereby enabling accurate coating deposition. Further, the nozzle arm may allow for a wide range of motion, giving the system of the present disclosure the ability to position the nozzle head at various angles or positions.

In some embodiments, the first stage actuator includes a first stage housing, and a first stage motor housed within the first stage housing. The first stage motor has a first stage motor shaft. A lead screw is coupled to the first stage motor shaft and adapted to be rotated by the first stage motor through the first stage motor shaft. A lead screw nut is rotationally coupled to the lead screw. Further, the first stage actuator includes a pair of side levers. Each of the pair of side levers is coupled to the lead screw nut at one end and coupled to the nozzle arm at another end. A rotation of the lead screw by the first stage motor shaft pushes the lead screw nut, and the lead screw nut subsequently pushes the pair of side levers to actuate a swivel motion of the nozzle arm about the first axis. The first stage actuator may utilize a lead screw mechanism to control the swivel motion of the nozzle arm. The lead screw mechanism may provide fine control over the nozzle arm's movement. Further, since the lead screw converts rotational motion into linear motion with minimal backlash, the system of the present disclosure may achieve precise positioning of the nozzle arm, which may be crucial for application of the engineering coating to the one or more components. Further, the lead screw may effectively transmit high torque with relatively low effort and may thereby allow the first stage actuator to generate significant force with a relatively small first stage motor. This may allow for a compact structure of the system.

In some embodiments, the swivel motion of the nozzle arm ranges between a first position and a second position in both planes of motion respectively. The ability to swivel in two planes of motion may provide enhanced manoeuvrability, allowing the at least one nozzle to cover a wider area of the one or more components to which the engineering coating may be applied. Further, with independent control of movement in the two planes of motion, the at least one nozzle may direct the engineering coating in the exact desired direction, leading to more efficient application of the engineering coating to the one or more components.

In some embodiments, the first position of the nozzle arm corresponds to the nozzle head being parallel to the second axis. The nozzle arm may allow for a wide range of motion, giving the system of the present disclosure the ability to position the nozzle head at various angles or positions. As an example, the nozzle head may be positioned in a home position when igniting and stabilizing the flame. The term “home position” according to the present disclosure may be defined as an initial position of the nozzle head with the nozzle head facing away from the one or more components to be coated with the engineering coating.

In some embodiments, the second position of the nozzle arm corresponds to the nozzle head being inclined with respect to the second axis. The nozzle arm may allow for a wide range of motion, giving the system of the present disclosure the ability to position the nozzle head at various angles or positions. As an example, the nozzle head may be positioned in a working position when applying engineering coating to the one or more components. The term “working position” according to the present disclosure may be defined as a position of the nozzle head with the nozzle head facing towards the one or more components to be coated with the engineering coating.

In some embodiments, the second stage actuator includes a second stage housing, and a second stage motor housed within the second stage housing. The second stage motor is adapted to actuate a rotational motion of the first stage actuator and the head section together about the second axis. The second stage motor by rotating the first stage actuator and the head section about the second axis may allow the system, and/or the first stage actuator and/or the head section to gain additional degrees of freedom. The inclusion of additional motor into the system of the present disclosure may allow for more complex movements and finer control, enabling the head section to be positioned with greater flexibility in multiple directions.

In some embodiments, the engineering coating material is selected from a MCrAlY bond coat and/or an yttria stabilized zirconia (YSZ) ceramic topcoat. The MCrAlY bond coat and the yttria-stabilized zirconia (YSZ) ceramic topcoat may offer several advantages, particularly in high-performance environments like gas turbines, jet engines, and other high- temperature applications. The MCrAlY layer may provide excellent protection against oxidation and corrosion by forming a stable, adherent oxide layer (such as alumina) on the surface of the one or more components on which the engineering coating may be applied. Further, this may prevent aggressive high-temperature oxidation that may otherwise degrade the engineering coating material over time. The MCrAlY layer may also enhance resistance to erosion from high-velocity gas flow and wear. Further, the yttria-stabilized zirconia's low thermal conductivity may significantly reduce the amount of heat that may reach the one or more components on which the engineering coating may be applied. This may improve its lifespan and performance of the one or more components on which the engineering coating may be applied.

In some embodiments, the deployment device is a snake robot. The snake robot may navigate through tight, confined spaces where traditional robots or machines may struggle. This makes them ideal for environments with complex geometries or narrow passages, such as inside of the gas turbine engine.

In a third aspect, there is provided a method for in-situ application of an engineering coating to one or more components using the apparatus. The method includes providing a deployment device, and further providing a source of engineering coating material coupled to the deployment device. The method further includes deploying the apparatus of the first aspect near the one or more components by the deployment device. The method further includes supplying, by the source of engineering coating material, the engineering coating material to the apparatus. The method further includes actuating the first stage actuator adapted to actuate the head section to swivel about a first axis. The method further includes actuating the second stage actuator adapted to actuate the head section and the first stage actuator together to rotate about a second axis. The second axis is orthogonal to the first axis. The method further includes applying, by the head section, the engineering coating material to the one or more components to form the engineering coating.

The method of the present disclosure may allow repairing of patches on the one or more components of a machine (e.g., a gas turbine engine). In applications where the one or more components are parts of the gas turbine engine, the method of the present disclosure may allow repairing of patches on the one or more components while the gas turbine engine is on-wing to minimise disruption of operation. In other words, for application of the engineering coating to the one or more components, the method does not require disassembly of the gas turbine engine, thereby preventing any loss of operational efficiency of the gas turbine engine. Moreover, the method of the present disclosure provides a process by which repairing of patches on the one or more components may be done in a time efficient and cost-efficient manner.

Further, by the method of the present disclosure, the apparatus may be brought in proximity to the gas turbine engine, or the apparatus may be at least partially inserted within the gas turbine engine for accessing and repairing of the one or more components by applying the engineering coating thereto. Specifically, the method of the present disclosure may provide forward movement to the apparatus to effectively apply the engineering coating to the one or more components. The method may also provide retract movement to the apparatus to avoid clashing against the backwall of a combustor. Hence, the method, by providing the forward and retract movement of the apparatus, may prevent the one or more components from overheating while the engineering coating is applied to the one or more components.

By selective swivelling movement of the head section and the combined rotary movement of the head section and the first stage actuator, the method of the present disclosure may allow the applicator end to be directed away from the one or more components during initial ignition and set-up so as to avoid create a poorly adhered coating patch. Therefore, the method may allow the apparatus to apply the engineering coating of desirable dimensions and shapes depending on the target area on the one or more components. Furthermore, by selective swivelling movement of the head section and the combined rotary movement of the head section and the first stage actuator the method may prevent the one or more components from overheating while the engineering coating is applied thereto.

In some embodiments, the method further includes providing one or more gas channels along the body section to the head section. By utilizing one or more gas channels, the method of the present disclosure may allow the apparatus to receive and carry the gases required for forming the engineering coating towards the head section.

In some embodiments, actuating the first stage actuator further includes rotating a lead screw by a first stage motor shaft such that the first stage motor shaft is coupled to a first stage motor housed within a first stage housing within the first stage actuator. Further, the method includes pushing a lead screw nut in response to rotation of the lead screw. Further, the method includes pushing a pair of side levers in response to pushing the lead screw nut such that each of the pair of side levers is coupled to the lead screw nut at one end and coupled to the nozzle arm at another end. Further, the method includes actuating a swivel motion of the nozzle arm about the first axis in response to pushing the pair of side levers. The first stage actuator may utilize a lead screw mechanism to control the swivel motion of the nozzle arm. The lead screw mechanism may provide fine control over the nozzle arm's movement. Further, since the lead screw converts rotational motion into linear motion with minimal backlash, the apparatus using the method of the present disclosure may achieve precise positioning of the nozzle arm, which may be crucial for application of the engineering coating to the one or more components. Further, the lead screw may effectively transmit high torque with relatively low effort and may thereby allow the first stage actuator to generate significant force with a relatively small first stage motor. This may allow for a compact structure of the apparatus.

In some embodiments, actuating the second stage actuator further includes actuating a rotational motion of the first stage actuator and the head section together about the second axis by a second stage motor. The second stage motor is housed within a second stage housing within the second stage actuator.

BRIEF DESCRIPTION OF THE DRAWINGS

Embodiments will now be described by way of example only with reference to the accompanying drawings, in which:

FIG. 1 shows a block diagram of a system for in-situ application of an engineering coating to one or more components;

FIG. 2 shows a perspective view of an apparatus for in-situ application of an engineering coating to one or more components;

FIG. 3 shows a perspective view of the apparatus of FIG. 2 illustrating some of the internal parts;

FIGS. 4A and 4B respectively show a front view and a side view of the apparatus;

FIG. 5 shows another side view of the apparatus illustrating some of the internal parts;

FIGS. 6A - 6C show perspective views of the apparatus to show a range of rotational movements of a first stage actuator and a head section together about a second axis;

FIGS. 7A and 7B respectively show a top view and a side view of the first stage actuator of a body section of the apparatus;

FIGS. 8A - 8D respectively show side views of the apparatus to show a range of swivelling movement of the head section about a first axis;

FIG. 9 shows an exploded view of the apparatus;

FIGS. 10A and 10B respectively show a rear view and a perspective view of the apparatus illustrating one or more gas channels;

FIG. 11 shows a side view of the apparatus illustrating the one or more gas channels;

FIG. 12 shows a perspective view of the head section and the body section of the apparatus;

FIGS. 13A shows a schematic view of the head section illustrating a flow path for a ceramic gas;

FIGS. 13B shows a schematic view of the head section illustrating a flow path for an oxy gas;

FIGS. 14A, 14B, 14C and 14D show different schematic views of the apparatus illustrating a cooling gas flow from the body section towards the head section; and

FIG. 15 is a flowchart depicting various steps of a method for in-situ application of an engineering coating to one or more components.

DETAILED DESCRIPTION

Various examples have been described, each of which comprise one or more combinations of features. It will be appreciated by those skilled in the art that, except where clearly mutually exclusive, any of the features may be employed separately or in combination with any other features and the invention extends to and includes all combinations and sub-combinations of one or more features described herein.

FIG. 1 shows a block diagram of a system 100 for in-situ application of an engineering coating 52 (shown in FIG. 2) to one or more components 50 (shown in FIG. 2), in accordance with an embodiment of the present disclosure. The system 100 includes an apparatus 200 and a deployment device 600 for deploying the apparatus 200 near the one or more components 50 to be coated. FIG. 2 shows a perspective view of the apparatus 200 for in-situ application of the engineering coating 52 to the one or more components 50, in accordance with an embodiment of the present disclosure.

In some embodiments, the one or more components 50 is a gas turbine engine component. As an example, the one or more components 50 may be hot-end components of the gas turbine engine, such as, but not limited to, turbine blades and combustor tiles.

Further, the system 100 includes a source 700 of an engineering coating material coupled to the deployment device 600 for supplying the engineering coating material to the apparatus 200. As an example, the source 700 may be removably coupled to the deployment device 600. As another example, the source 700 may be integrally formed with the deployment device 600. Further, the source 700 of engineering coating material may be fluidly coupled to the apparatus 200. As an example, the source 700 of engineering coating material may be fluidly coupled to the apparatus 200 via a silicone flexible tubing. In some embodiments, the engineering coating material is selected from a MCrAlY bond coat and/or an yttria stabilized zirconia (YSZ) ceramic topcoat, depending on the one or more components 50 to be coated for repair, amongst other factors.

The deployment device 600 may be configured to be held at a static position proximal to the gas turbine engine, or within the gas turbine engine, such that the apparatus 200 may be able to access and repair the component 50 of the gas turbine engine by depositing the engineering coating 52 on areas of delamination of the component 50. Preferably, the deployment device 600 is a snake robot.

The apparatus 200 includes a head section 300 adapted to selectively apply the engineering coating 52 to the one or more components 50. The head section 300 includes a nozzle head 306 and a nozzle arm 308 coupled to the nozzle head 306. As an example, the nozzle head 306 and the nozzle arm 308 may preferably be removably coupled to each other in any known manner in the related art. As another example, the nozzle head 306 and the nozzle arm 308 may be integrally formed with each other.

The head section 300 is configured to selectively apply the engineering coating 52 to the one or more components 50 by the nozzle head 306. As an example, the nozzle head 306 may include an integrated ignition source. Further, the nozzle head 306 includes an applicator end 302. In other words, the head section 300 includes the applicator end 302 which further includes at least one nozzle 310. The at least one nozzle 310 is configured to selectively apply the engineering coating 52 to the one or more components 50 via at least one nozzle hole 312. The at least one nozzle hole 312 may have any shape and size as per application requirements. As an example, the at least one nozzle hole 312 may include multiple nozzle holes 312 of similar or different shapes and sizes. The shapes may be selected from a circular shape, a rectangular shape, an oval shape, or any other shapes which may be envisioned within the scope of the present disclosure.

Further, the head section 300 includes a coupling end 304. The coupling end 304 is formed opposite to the applicator end 302 and spaced apart from the applicator end 302. The coupling end 304 is configured as an end of the nozzle arm 308.

With continuous reference to FIG. 2, the apparatus 200 further includes a body section 400. As an example, the body section 400 may be made from a metal, such as stainless steel. As another example, the body section 400 may be made from a suitable stiff polymer. The body section 400 is coupled to the head section 300 at the coupling end 304 and adapted to actuate the head section 300.

The body section 400 includes a first stage actuator 402 adapted to actuate the head section 300 to swivel about a first axis X-X’. The body section 400 further includes a second stage actuator 404 adapted to actuate the head section 300 and the first stage actuator 402 together to rotate about a second axis Y-Y’. The second axis Y-Y’ is orthogonal to the first axis X-X’. The second axis Y-Y’ is defined along a longitudinal direction of the body section 400, while the first axis X-X’ is defined along a lateral direction of the body section 400. The second axis Y-Y’ and the first axis X-X’ intersect at a point proximal the coupling end 304.

FIG. 3 shows a perspective view of the apparatus 200 illustrating some of the internal parts of the body section 400. Referring to FIGS. 1 to 3, the body section 400 includes the first stage actuator 402 such that the first stage actuator 402 includes a first stage housing 406, and a first stage motor 408 housed within the first stage housing 406. As an example, the first stage motor 408 is a stepper motor. The first stage motor 408 has a first stage motor shaft 409 (as shown later in FIG. 9). Further, the first stage actuator 402 includes a lead screw 412 coupled to the first stage motor shaft 409 and adapted to be rotated by the first stage motor 408 through the first stage motor shaft 409.

The body section 400 further includes the second stage actuator 404 such that the second stage actuator 404 includes a second stage housing 414, and a second stage motor 416 housed within the second stage housing 414. As an example, the second stage motor 416 is a stepper motor. The second stage motor 416 is adapted to actuate a rotational motion of the first stage actuator 402 and the head section 300 together about the second axis Y-Y’.

FIGS. 4A and 4B respectively show a front view and a side view of the apparatus 200. The head section 300 is configured to exhibit the swivel movement when actuated alone by the first stage actuator 402. Further the head section 300 is configured to exhibit the rotary movement when actuated alone by the second stage actuator 404. Furthermore, the head section 300 is configured to exhibit a combination of swivel and rotary movement when actuated simultaneously by both the first stage actuator 402 and the second stage actuator 404. In other words, the head section 300 is configured to exhibit movement about the first axis X-X’ when actuated alone by the first stage actuator 402. Further the head section 300 is configured to exhibit movement about the second axis Y-Y’ when actuated alone by the second stage actuator 404. Furthermore, the head section 300 is configured to exhibit movement about both the first axis X-X’ and the second axis Y-Y’ when actuated simultaneously by both the first stage actuator 402 and the second stage actuator 404. The operation of the first stage actuator 402 and the second stage actuator 404 is independent of each other. The first stage actuator 402 and the second stage actuator 404 may operate simultaneously or individually as per the application requirement, component dimensions, component shape, amongst other operating factors.

FIG. 5 shows another side view of the apparatus 200 illustrating some of the internal parts of the body section 400. The second stage motor 416 is adapted to rotate the first stage actuator 402 at a junction 410 between the first stage actuator 402 and the second stage actuator 404. A second stage motor shaft 417 (shown in FIG. 9) is fixed together with the first stage actuator 402 such that the rotation of the second stage motor 416 is directly proportional to the rotation of the first stage actuator 402.

FIGS. 6A, 6B and 6C show perspective views of the apparatus 200 to show a range of rotational movements of the first stage actuator 402 and the head section 300 together about the second axis Y-Y’. As illustrated in FIGS. 6A, 6B and 6C, the nozzle arm 308, the nozzle head 306, and the first stage actuator 402 together rotate about the second axis Y-Y’. The head section 300 and the first stage actuator 402 together are configured to rotate about the second axis Y-Y’ due to the actuation provided by the second stage actuator 404, in particular the second stage motor 416. The second stage motor 416 works independent of the working of the first stage motor 408. The second stage motor 416 is configured to selectively rotate the head section 300 and the first stage actuator 402 together about the second axis Y-Y’ during the application of the engineering coating 52. The second stage motor 416 is configured to selectively rotate the head section 300 and the first stage actuator 402 in a clockwise direction and an anticlockwise direction about the second axis Y-Y’. The second stage motor 416 is configured to control the rotational speed of the head section 300 and the first stage actuator 402. As an example, the head section 300 may move in the range of -45^o to +45^o relative to the second axis Y-Y’. As another example, the head section 300 may move in the range of -90^o to +90^o relative to the second axis Y-Y’. As another example, the head section 300 may move around a complete circle, i.e., 360^o in either the clockwise direction or the anticlockwise direction.

The rotational motion about the second axis Y-Y’ may allow the head section 300, particularly the nozzle head 306 to be directed away from the one or more components 50 of the gas turbine engine towards a home position during initial ignition and set-up, particularly given that shortly after ignition the flame is sooty which (if directed to the area of interest) may create a poorly adhered coating patch. The home position may be any position shown in FIGS. 6A, 6B and 6C, depending upon the location of the one or more components 50, as well as the shape and dimensions of the one or more components 50. Further, during deposition, moving the nozzle head 306 in an arc nominally from -45^o to +45^o may create a wide patch of coating.

With continuous reference to FIGS. 6A, 6B and 6C, the rotational motion of the nozzle arm 308 ranges between a first position P3 and a second position P4 in a plane of motion. When the second stage actuator 404 actuates the first stage actuator 402 about the second axis Y-Y’ by 45^o in the anticlockwise direction, the head section 300 also rotates by 45^o in the anticlockwise direction to the first position P3 as shown in FIG. 6A.

When the second stage actuator 404 does not actuate the first stage actuator 402 about the second axis Y-Y’, both the first stage actuator 402 and the head section 300 remain in neutral position as shown in FIG. 6B.

When the second stage actuator 404 actuates the first stage actuator 402 about the second axis Y-Y’ by 45^o in the clockwise direction, the head section 300 also rotates by 45^o in the clockwise direction to the second position P4 as shown in FIG. 6C.

FIGS. 7A and 7B respectively show a top view and a side view of the first stage actuator 402. The first stage actuator 402 further includes a lead screw nut 418 rotationally coupled to the lead screw 412. The rotation of the lead screw 412 by the first stage motor shaft 409 results in a translatory motion of the lead screw nut 418 towards and away from the first stage motor 408. In other words, when the first stage motor 408 rotates, the lead screw 412 rotates, which then in turn moves the lead screw nut 418 forward or backwards depending on the direction of rotation of the first stage motor 408.

Further, the first stage actuator 402 includes a pair of side levers 420. Each of the pair of side levers 420 is coupled to the lead screw nut 418 at one end and coupled to the nozzle arm 308 at another end. The rotation of the lead screw 412 by the first stage motor shaft 409 pushes the lead screw nut 418, and the lead screw nut 418 subsequently pushes the pair of side levers 420 to actuate a swivel motion of the nozzle arm 308 about the first axis X-X’. The swivel motion of the nozzle arm 308 about the first axis X-X’ is controlled by the first stage motor 408.

FIGS. 8A, 8B, 8C and 8D respectively show side views of the apparatus 200 to show swivelling movement of the head section 300 about the first axis X-X’. Each of the pair of side levers 420 is coupled to the nozzle arm 308 using a dowel pin 424. The dowel pin 424 connecting the pair of side levers 420 and the nozzle arm 308 passes through a pair of arc shaped cavities 422 provided with the first stage housing 406 of the first stage actuator 402. Each of the pair of arc shaped cavities 422 is disposed on the first stage housing 406 on either side of the second axis Y-Y’. The pair of arc shaped cavities 422 is defined such that the first axis X-X’ passes through the pair of arc shaped cavities 422. Further, each of the pair of arc shaped cavities 422 is mirror image of each other. The first stage housing 406 and the nozzle arm 308 are coupled to each other using the dowel pin 424 such that the rotation of the lead screw 412 by the first stage motor shaft 409 pushes the lead screw nut 418, and the lead screw nut 418 subsequently pushes the pair of side levers 420 to actuate the swivel motion of the nozzle arm 308 about the first axis X-X’.

The swivel motion of the nozzle arm 308 ranges between a first position P1 and a second position P2 in a plane of motion. The first position P1 of the nozzle arm 308 corresponds to the nozzle head 306 being parallel to the second axis Y-Y’ as shown in FIG. 8A. The second position P2 of the nozzle arm 308 corresponds to the nozzle head 306 being inclined with respect to the second axis Y-Y’ as shown in FIG. 8D. In other words, due to the actuation provided the first stage motor 408, the nozzle arm 308 moves between a position parallel to the second axis Y-Y’ and a position inclined with respect to the second axis Y-Y’.

Further, in the first position P1 of the nozzle arm 308 as shown in FIG. 8A, the lead screw nut 418 is located at the start of the lead screw 412 proximal the first stage motor 408, and the dowel pin 424 is located at the right most end of the pair of arc shaped cavities 422 when seen along the second axis Y-Y’.

Further, when the lead screw nut 418 moves on the lead screw 412 and the dowel pin 424 reaches proximal the middle of the pair of arc shaped cavities 422 from the right most end of the pair of arc shaped cavities 422 as shown in FIG. 8B, the nozzle arm 308 reaches in an angular position at substantially 45^o angle from the first position P1.

Upon further movement of the lead screw nut 418 on the lead screw 412, when the dowel pin 424 reaches proximal the middle of the pair of arc shaped cavities 422 towards the left most end of the pair of arc shaped cavities 422 as shown in FIG. 8C, the nozzle arm 308 reaches in an angular position at substantially 90^o anglefrom the first position P1.

Further, when the movement of the lead screw nut 418 on the lead screw 412 results in the dowel pin 424 reaching the left most end of the pair of arc shaped cavities 422 as shown in FIG. 8D, the nozzle arm 308 reaches in an angular position at substantially 135^o anglefrom the first position P1. In other words, when the movement of the lead screw nut 418 on the lead screw 412 results in the dowel pin 424 reaching the left most end of the pair of arc shaped cavities 422, the nozzle arm 308 reaches the second position P2.

In other words, the head section 300 is configured to swivel about the first axis X-X’ due to the actuation provided by the first stage actuator 402. The nozzle arm 308 is configured to swivel about the first axis X-X’ due to the actuation provided by the first stage actuator 402, in particular the first stage motor 408. The first stage motor 408 is configured to operate independent of the second stage motor 416 and further configured to selectively swivel the head section 300 about the first axis X-X’ during the application of the engineering coating 52. The first stage motor 408 is configured to control the swivel speed and direction of the head section 300 during rotation about the first axis X-X’. The first stage motor 408 is configured to selectively rotate the head section 300 and the first stage actuator 402 in the clockwise direction and the anticlockwise direction about the first axis X-X’.

Further, the swivel motion about the first axis X-X’ may allow the head section 300, particularly the nozzle head 306 to be directed away from the one or more components 50 of the gas turbine engine towards the home position during initial ignition and set-up, particularly given that shortly after ignition the flame is sooty which (if directed to the area of interest) may create a poorly adhered coating patch. The home position may be any position shown in FIGS. 8A, 8B, 8C and 8D, depending upon the location of the one or more components 50 inside of the gas turbine engine, as well as the shape and dimensions of the one or more components 50.

Thus, the apparatus 200, by using the swivel plus rotary movement (as illustrated in FIGS. 6A, 6B and 6C and FIGS. 8A, 8B, 8C and 8D respectively) in the head section 300, may form a rectangular patch to help contain any in-service coating loss. Further, the apparatus 200, by using the swivel plus rotary movement in the head section 300, may ensure that there may be no dwell points (which may overheat the surface of the component 50) and no regions of the component 50 may be missed (which may create a poor coating patch).

FIG. 9 shows an exploded view of the apparatus 200. The second stage actuator 404 includes a second stage mount 415 configured to house the second stage motor 416. The second stage motor 416 includes the second stage motor shaft 417. The second stage mount 415 together with the second stage motor 416 is removably housed within the second stage housing 414 using a plurality of screw fasteners 421 and a clamp 419.

Further, the second stage mount 415 includes a second stage motor attachment 413. The second stage motor attachment 413 extends from the second stage mount 415 such that the second stage motor shaft 417 is at least partially housed within the second stage motor attachment 413. The second stage motor attachment 413 is annularly shielded by a second stage cap 423.

Further, the second stage housing 414 is coupled to the first stage housing 406 or the second stage actuator 404 is coupled to the first stage actuator 402 by a first stage cap 405. In other words, the second stage cap 423 and the first stage cap 405 are coupled to each other at the junction 410 such that the second stage actuator 404 is coupled to the first stage actuator 402 to actuate the first stage actuator 402 and the head section 300 together. Further, the first stage cap 405 is removably housed in a first stage mount 407. The first stage mount 407 and the first stage cap 405 are removably coupled to each other using a shoulder screw 411. The first stage mount 407 is configured to house the first stage motor 408. The first stage motor 408 includes the first stage motor shaft 409. The first stage mount 407 together with the first stage motor 408 is removably housed within the first stage housing 406 using the plurality of screw fasteners 421.

Further, the first stage housing 406 also houses the lead screw 412. The lead screw 412 is coupled to the first stage motor shaft 409 and adapted to be rotated by the first stage motor 408 through the first stage motor shaft 409. The lead screw nut 418 is rotationally coupled to the lead screw 412 such that the rotation of the lead screw 412 by the first stage motor shaft 409 results in a translatory motion of the lead screw nut 418 towards and away from the first stage motor 408. In other words, when the first stage motor 408 rotates, the lead screw 412 rotates, which then in turn moves the lead screw nut 418 forward or backwards depending on the direction of rotation of the first stage motor 408.

The apparatus 200 assembled in the manner as described above may allow repairing of patches on the one or more components 50 while the gas turbine engine is on-wing to minimise disruption of operation. In other words, for application of the engineering coating 52 to the one or more components 50, there may be no need for disassembly of the gas turbine engine, thereby preventing any loss of operational efficiency of the gas turbine engine. Moreover, the repairing of patches on the one or more components 50 may be done in a time efficient and cost-efficient manner. Further, the apparatus 200 while applying the engineering coating 52 to the one or more components 50 may not impart any residual stress or microstructural changes in the one or more components 50. This may be due to selective swivelling movement of the head section 300 about the first axis X-X’, and the combined rotary movement of the head section 300 and the first stage actuator 402 about the second axis Y-Y’.

FIGS. 10A and 10B respectively show a rear view and a perspective view of the apparatus 200, in accordance with an embodiment of the present disclosure. The apparatus 200 further includes one or more gas channels 500 provided along the body section 400 to the head section 300. FIG. 11 shows a side view of the apparatus 200 illustrating the one or more gas channels 500. The one or more gas channels 500 includes a first channel 502 for a ceramic powder carried within an inert gas and a second channel 504 for a fuel gas (fuel source) in liquid or gaseous form. As an example, the fuel gas may be an oxy gas. As an example, the first channel 502 and the second channel 504 may constitute a silicon tube. The first channel 502 as well as the second channel 504 extends from the rear of the apparatus 200, in particular the second stage actuator 404 of the apparatus 200 towards the front of the second stage actuator 404. Further, the first channel 502 as well as the second channel 504 extend towards the head section 300 (as shown in FIG. 11).

FIG. 12 shows a perspective view of the head section 300 and the body section 400. The head section includes a first hole 314 and a second hole 316. The first channel 502 and the second channel 504 extends from the body section 400 towards the head section 300 via the first hole 314 and the second hole 316, respectively, provided with the head section 300, particularly a portion of the nozzle arm 308. As an example, the first channel 502 and the second channel 504 may be push fit into the first hole 314 and the second hole 316, respectively, and may further be secured with glue.

FIGS. 13A and 13B show schematic views illustrating flow paths within the head section 300 for the ceramic gas and the oxy gas, respectively. The ceramic gas enters via the first hole 314 into the head section 300, and flows within the nozzle arm 308 as well as the nozzle head 306 as shown in FIG. 13A, to reach the nozzle 310. The flow of ceramic gas from the first hole 314 to the nozzle 310 may be non-uniform. The oxy gas enters via the second hole 316 into the head section 300, and flows within the nozzle arm 308 as well as the nozzle head 306 as shown in FIG. 13B, to reach the nozzle 310. The flow of ceramic gas from the second hole 316 to the nozzle 310 may be non-uniform.

FIGS. 14A, 14B, 14C and 14D show a cooling gas flow from within the body section 400 towards the head section 300 of the apparatus 200. The one or more gas channels 500 includes a third channel 506 for a cooling gas in addition to the first channel 502 for the ceramic powder carried within the inert gas, and the second channel 504 for the fuel gas in liquid or gaseous form. The third channel 506 starts from two elongated holes 508, 510 (as shown in FIG. 14A) that span at least partially across the second stage mount 415. The cooling gas flow extends from the two elongated holes 508, 510 and converge into a single flow (as shown in FIG. 14B) to move inside of the second stage mount 415 via a groove 512 formed on the second stage mount 415. From the inside of the second stage mount 415, the cooling gas flow moves in a path as shown in FIG. 14C towards a flow pipe 514 housed within the first stage housing 406. The flow pipe 514 is disposed on both sides of the first stage motor 408 housed within the first stage housing 406. Further, from each of the flow pipes 514, the cooling gas flows via, for example, a silicon tube towards the body section 400 and enters the body section 400 via a third hole 318 and a fourth hole (not shown) located on either side of the nozzle arm 308 relative to the second axis Y-Y’.

FIG. 15 is a flowchart depicting various steps of a method 800 for in-situ application of the engineering coating 52 (shown in FIG. 2) to the one or more components 50 (shown in FIG. 2) using the apparatus 200.

At step 802, the method 800 includes providing the deployment device 600. The deployment device 600 is a snake robot. At step 804, the method 800 includes providing the source 700 of the engineering coating material coupled to the deployment device 600. At step 806, the method 800 includes deploying the apparatus 200 near the one or more components 50 by the deployment device 600. The apparatus 200 includes the head section 300 adapted to selectively apply the engineering coating 52 to the one or more components 50.

The apparatus 200 further includes the body section 400. The body section 400 is coupled to the head section 300 at the coupling end 304 and adapted to actuate the head section 300. The body section 400 includes the first stage actuator 402 adapted to actuate the head section 300 to swivel about the first axis X-X’, and a second stage actuator 404 adapted to actuate the head section 300 and the first stage actuator 402 together to rotate about the second axis Y-Y’. The second axis Y-Y’ is orthogonal to the first axis X-X’.

At step 808, the method 800 includes supplying, by the source 700 of the engineering coating material, the engineering coating material to the apparatus 200. At step 810, the method 800 includes actuating the first stage actuator 402 adapted to actuate the head section 300 to swivel about the first axis X-X’. The method 800, for actuating the first stage actuator 402, further includes rotating the lead screw 412 by the first stage motor shaft 409 such that the first stage motor shaft 409 is coupled to the first stage motor 408 housed within the first stage housing 406 within the first stage actuator 402. Actuating the first stage actuator further includes pushing the lead screw nut 418 in response to rotation of the lead screw 412. Actuating the first stage actuator further includes pushing the pair of side levers 420 in response to pushing the lead screw nut 418 such that each of the pair of side levers 420 is coupled to the lead screw nut 418 at one end and coupled to the nozzle arm 308 at another end. Actuating the first stage actuator further includes actuating a swivel motion of the nozzle arm 308 about the first axis X-X’ in response to pushing the pair of side levers 420.

At step 812, the method 800 includes actuating the second stage actuator 404 adapted to actuate the head section 300 and the first stage actuator 402 together to rotate about the second axis Y-Y’. The method 800, for actuating the second stage actuator 404, further includes actuating, by the second stage motor 416, a rotational motion of the first stage actuator 402 and the head section 300 together about the second axis Y-Y’. The second stage motor 416 is housed within a second stage housing 414 within the second stage actuator 404.

At step 814, the method 800 includes applying, by the head section 300, the engineering coating material to the one or more components 50 to form the engineering coating 52.

The method 800 further includes providing one or more gas channels 500 (shown in FIG. 14A) along the body section 400 to the head section 300.

The apparatus, system, and method of the present disclosure may improve an in-situ application of an engineering coating to one or more components. Specifically, the apparatus, system, and method may facilitate in-situ application of the engineering coating to one or more components using swivel movement and rotation of the head section.

Various examples have been described, each of which comprise various combinations of features. It will be appreciated by those skilled in the art that, except where clearly mutually exclusive, any of the features may be employed separately or in combination with any other features and the invention extends to and includes all combinations and sub-combinations of one or more features described herein.