Methods 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 for 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, a distance of the gap extending from about 0.010 inches to about 0.050 inches from the edge to the shield, 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 . The 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 . The 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 - 8 . (canceled) 
     
     
         9 . The 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 - 20 . (canceled) 
     
     
         21 . The method in accordance with  claim 2 , wherein positioning a non-consumable shield adjacent to an edge of the component comprises reducing the thickness of the electroplated edge of the component by at least about 0.0001 inches relative to a non-shielded component. 
     
     
         22 . The method in accordance with  claim 1 , wherein positioning a non-consumable shield adjacent to an edge of the component comprises:
 displacing at least a portion of an electric field away from the edge using a non-conductive shield positioned adjacent to the edge; and   reducing a rate of electroplating at the edge based on the displacement of the electric field.   
     
     
         23 . The method in accordance with  claim 1 , wherein positioning a non-consumable shield adjacent to an edge of the component comprises:
 selecting a shield sized to facilitate displacing an electric field away from the edge; and   depositing a coating on the edge that is substantially uniform with respect to the coating deposited on a remainder of the component.   
     
     
         24 . The method in accordance with  claim 1 , wherein positioning a non-consumable shield adjacent to an edge of the component comprises selecting a non-consumable shield that has a substantially tubular shape and a convex outer surface. 
     
     
         25 . The method in accordance with  claim 24 , wherein positioning a non-consumable shield adjacent to an edge of the component comprises extending the convex outer surface of the shield beyond the edge such that the fluid flow restriction is formed adjacent to the edge. 
     
     
         26 . The 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 an electrical flux restriction is formed adjacent to the edge. 
     
     
         27 . The method in accordance with  claim 1 , wherein positioning a non-consumable shield adjacent to an edge of the component comprises positioning a non-consumable shield adjacent to a trailing edge of the component, wherein the component is a high pressure turbine nozzle vane. 
     
     
         28 . The method in accordance with  claim 1 , wherein positioning a non-consumable shield adjacent to the edge of the component comprises extending the non-consumable shield along a longitudinal axis that is substantially parallel to the edge of the component. 
     
     
         29 . A method for coating a gas turbine engine component including a convex outer surface, a concave outer surface, and a trailing edge defined therebetween, said method comprising:
 submerging the component in a quantity of electrolyte solution;   inducing an electrical current from an anode to the component through the electrolyte solution such that a coating is applied to the component; and   restricting fluid flow adjacent to the trailing edge such that the coating is substantially uniformly applied to the convex outer surface, the concave outer surface, and the trailing edge.   
     
     
         30 . The method in accordance with  claim 29 , wherein restricting fluid flow adjacent to the trailing edge comprises positioning a non-conductive shield adjacent to the trailing edge such that at least a portion of an electric field generated is displaced away from the trailing edge. 
     
     
         31 . The method in accordance with  claim 30 , wherein positioning a non-consumable shield adjacent to the trailing edge comprises selecting a size of the shield to facilitate displacing the electric field away from the trailing edge. 
     
     
         32 . The method in accordance with  claim 29 , wherein restricting fluid flow adjacent to the trailing edge comprises positioning a non-consumable shield adjacent to the trailing edge such that a gap is defined between the shield and the trailing edge and such that a gap distance therebetween is from about 0.010 inches to about 0.050 inches. 
     
     
         33 . The method in accordance with  claim 32 , wherein positioning a non-consumable shield adjacent to the trailing edge comprises selecting a non-consumable shield that has a substantially tubular shape and a convex outer surface. 
     
     
         34 . The method in accordance with  claim 33 , wherein selecting a non-consumable shield comprises selecting a non-consumable shield that has a diameter that is greater than a thickness of the trailing edge. 
     
     
         35 . The method in accordance with  claim 32 , wherein positioning a non-consumable shield adjacent to the trailing edge comprises extending the non-consumable shield along a longitudinal axis that is substantially parallel to the trailing edge of the component. 
     
     
         36 . The method in accordance with  claim 29 , wherein submerging the component comprises:
 coupling the component and a non-consumable shield to a support structure, wherein the shield is positioned adjacent to the trailing edge of the component; and   submerging the support structure in the quantity of electrolyte solution.