Methods and apparatus for fabricating gas turbine engines

Abstract

Methods and apparatus of fabricating gas turbine engine components are provided. The method includes positioning a non-consumable shield adjacent to an edge of the component such that a gap is defined between the shield and the component, wherein the shield and gap form a fluid flow restriction adjacent to the edge, and inducing an electrical current from an anode to the component through an electrolyte bath such that a coating is applied to the component.

1 . A method of fabricating a gas turbine engine component, said method comprising: 
 positioning a non-consumable shield adjacent to an edge of the component such that a gap is defined between the shield and the component, wherein the shield and gap form a fluid flow restriction adjacent to the edge; and    inducing an electrical current from an anode to the component through an electrolyte bath such that a coating is applied to the component.    
   
   
       2 . A method in accordance with  claim 1  further comprising electroplating the component such that a thickness of the plating coating on the edge of the component is substantially equal to a thickness of the plating coating across the surface of the component.  
   
   
       3 . A method in accordance with  claim 1  wherein inducing an electrical current from an anode to the component comprises coupling the component as a cathode in the electrical circuit.  
   
   
       4 . A method in accordance with  claim 1  wherein positioning a non-consumable shield adjacent to an edge of the component comprises positioning a non-conductive shield adjacent to the edge such that at least a portion of an electric field generated is displaced away from the edge.  
   
   
       5 . A method in accordance with  claim 1  wherein positioning a non-consumable shield adjacent to an edge of the component comprises selecting a size of the shield to facilitate displacing an electric field away from the edge, such that the coating deposited on the edge is substantially uniform with respect to the coating deposited on the component.  
   
   
       6 . A method in accordance with  claim 1  wherein positioning a non-consumable shield adjacent to an edge of the component comprises positioning a non-conductive shield adjacent to the edge of the component.  
   
   
       7 . A method in accordance with  claim 1  wherein positioning a non-consumable shield adjacent to an edge of the component comprises positioning a shield adjacent to the edge of the component such that a width of the gap is equal to between approximately 0.010 inches and approximately 0.050 inches.  
   
   
       8 . A method in accordance with  claim 1  wherein positioning a non-consumable shield adjacent to the edge of the component comprises positioning the shield adjacent to the edge of the component such that a width of the gap is equal to approximately 0.030 inches.  
   
   
       9 . A method in accordance with  claim 1  wherein positioning a non-consumable shield adjacent to the edge of the component comprises positioning the shield adjacent to the edge, such that the shield has a contour that substantially matches a contour of the edge.  
   
   
       10 . An electroplating apparatus comprising: 
 an electroplating bath comprising an electrolytic solution;    a power source;    an anode coupled to said power source;    a component coupled to said power source and immersed within said electrolytic solution, said component comprising a plating surface bordered by an edge; and    a non-consumable shield positioned adjacent said component edge such that a gap is defined between said edge and said shield, said shield and said gap forming a fluid flow restriction adjacent to said edge.    
   
   
       11 . An electroplating apparatus in accordance with  claim 10  wherein said component is coupled to said power source as a cathode.  
   
   
       12 . An electroplating apparatus in accordance with  claim 10  wherein said shield is fabricated from a non-conductive material.  
   
   
       13 . An electroplating apparatus in accordance with  claim 10  wherein said shield is fabricated from a plastic material.  
   
   
       14 . An electroplating apparatus in accordance with  claim 10  wherein said shield is configured to displace at least a portion of an electric field generated away from said edge.  
   
   
       15 . An electroplating apparatus in accordance with  claim 10  wherein said shield is configured to facilitate substantially uniformly plating a metallic film over said plating surface and said edge.  
   
   
       16 . An electroplating apparatus in accordance with  claim 10  wherein a width of said gap is equal to between approximately 0.010 inches and approximately 0.050 inches.  
   
   
       17 . An electroplating apparatus in accordance with  claim 10  wherein a width of said gap is approximately 0.030 inches.  
   
   
       18 . An electroplating apparatus comprising: 
 an electroplating bath comprising an electrolytic solution comprising platinum;    a power source;    an anode coupled to said power source;    a component to be electroplated coupled to said power source and immersed within said electrolytic solution, said component comprising a plating surface and an edge; and    a non-consumable shield positioned adjacent said edge such that a gap is defined between said edge and said shield, said shield and said gap forming a fluid flow restriction adjacent to said edge, said shield configured to displace an electric field away from said edge to facilitate reducing an amount of electroplating deposited on said edge.    
   
   
       19 . An electroplating apparatus in accordance with  claim 18  wherein said shield is sized to have a diameter that is larger than said diameter of said edge.  
   
   
       20 . An electroplating apparatus in accordance with  claim 18  wherein said shield comprises a body having a contour that is substantially similar to a contour of said edge such that a width of said gap is substantially constant along said edge.