Turbine component pattern forming method

Abstract

A method of forming a pattern comprising a plurality of recesses within a turbine component is disclosed. The method includes simultaneously dissolving a plurality of portions of a selected section of the turbine component, thereby defining the plurality of recesses of the pattern.

1 . A method of forming a pattern comprising a plurality of recesses within a turbine component, the method comprising:
 simultaneously dissolving a plurality of portions of a selected section of the turbine component, thereby defining the plurality of recesses of the pattern.   
   
   
       2 . The method of  claim 1 , wherein:
 the selected section of the turbine component comprises a plurality of selected sections of a plurality of turbine components; and   the step of simultaneously dissolving comprises simultaneously dissolving the plurality of portions of each of the plurality of selected sections.   
   
   
       3 . The method of  claim 1 , wherein the plurality of portions is a first plurality of portions, the method further comprising:
 applying a mask upon a second plurality of portions of the selected section of the turbine component.   
   
   
       4 . The method of  claim 3 , wherein the step of dissolving comprises:
 applying an electric potential via a power supply to the turbine component and to an electrode; and   permitting a flow of current between the electrode and the turbine component through an electrolyte.   
   
   
       5 . A method of forming a pattern comprising a plurality of recesses within a coating disposed upon a turbine component, the method comprising:
 simultaneously dissolving a plurality of portions of the coating disposed upon a selected section of the turbine component, thereby defining the plurality of recesses of the pattern.   
   
   
       6 . The method of  claim 5 , wherein:
 the step of simultaneously dissolving comprises simultaneously dissolving a plurality of portions of the coating disposed upon a selected airfoil shroud, at least one of the coating and the airfoil shroud comprising a concave curvature.   
   
   
       7 . The method of  claim 5 , wherein:
 the selected section of the turbine component comprises a plurality of selected sections of a plurality of turbine components; and   the step of simultaneously dissolving comprises simultaneously dissolving the plurality of portions of the coating disposed upon each of the plurality of selected sections.   
   
   
       8 . The method of  claim 5 , wherein the coating comprises at least one of nickel, cobalt, chromium, aluminum, yttrium, rhenium, rhodium, ruthenium, palladium, platinum, niobium, molybdenum, silicon, hafnium, iron, manganese, gadolinium, lanthanum, and alloys thereof. 
   
   
       9 . The method of  claim 5 , wherein the plurality of portions is a first plurality of portions, the method further comprising:
 applying a mask upon a second plurality of portions of the coating.   
   
   
       10 . The method of  claim 9 , wherein:
 the step of dissolving comprises:
 selecting an etchant to dissolve the coating; and 
 exposing the coating and the mask to the etchant; 
   the step of applying comprises applying a mask that is chemically resistant to the etchant; and   the method further comprises preventing dissolving of the second plurality of portions of the coating, thereby defining a plurality of protrusions of the pattern.   
   
   
       11 . The method of  claim 10 , wherein the step of selecting an etchant comprises selecting at least one of hydrofluoric acid, sulfuric acid, nitric acid, and combinations thereof. 
   
   
       12 . The method of  claim 9 , wherein the step of dissolving comprises:
 applying an electric potential via a power supply to the coating and an electrode; and   permitting a flow of current between the electrode and the coating through an electrolyte.   
   
   
       13 . The method of  claim 12 , wherein the step of applying an electric potential comprises applying a pulsed DC electric potential. 
   
   
       14 . The method of  claim 13 , the step of applying a pulsed DC electric potential comprises applying alternating cathodic and anodic biased pulses. 
   
   
       15 . The method of  claim 12 , wherein the electrolyte comprises at least one of:
 hydrofluoric silicate;   ammonium fluorosilicate;   fluorosilic acid;   an aqueous solution of at least one of:
 sodium chloride; 
 sodium nitrate; and 
 sodium bromide; and 
   combinations thereof.   
   
   
       16 . The method of  claim 12 , wherein:
 the step of applying a mask comprises applying an electrically insulating mask; and   the method further comprises preventing dissolving of the second plurality of portions of the coating, thereby defining a plurality of protrusions of the pattern.   
   
   
       17 . The method of  claim 9 , wherein the step of applying comprises:
 cleaning a surface of the coating;   depositing a mask material directly upon the second plurality of portions of the coating; and   applying an activator to cure the deposited mask material, thereby defining the mask disposed upon the second plurality of portions of the coating.   
   
   
       18 . The method of  claim 17 , wherein the depositing comprises guiding a direct write tool via robotic control. 
   
   
       19 . The method of  claim 5 , further comprising:
 positioning an electrode comprising a plurality of protrusions in a pattern defining the plurality of recesses such that the plurality of protrusions are disposed corresponding to a desired location of the plurality of recesses;   wherein the step of simultaneously dissolving comprises:
 applying an electric potential via a power supply to the coating and the electrode; and 
 permitting a flow of current between the electrode and the coating through an electrolyte. 
   
   
   
       20 . The method of  claim 19 , wherein the step of applying comprises applying a pulsed DC electric potential. 
   
   
       21 . The method of  claim 5 , further comprising:
 selecting a material for depositing upon the coating;   depositing the material upon the coating to define one or more protrusions of the pattern; and   applying an appropriate activator to consolidate the deposited material.