Chapter 75. Rule-Based Software Tool to Specify the Manufacturing Process Parameters for a Countoured EB-PVD Coating on a PW4000 Second Stage Turbine Blade

  1. Waltraud M. Kriven and
  2. Hua-Tay Lin
  1. R. D. Sisson Jr.1,
  2. W. C. S. Weir1 and
  3. S. Bose2

Published Online: 26 MAR 2008

DOI: 10.1002/9780470294826.ch75

27th Annual Cocoa Beach Conference on Advanced Ceramics and Composites: B: Ceramic Engineering and Science Proceedings, Volume 24, Issue 4

27th Annual Cocoa Beach Conference on Advanced Ceramics and Composites: B: Ceramic Engineering and Science Proceedings, Volume 24, Issue 4

How to Cite

Sisson, R. D., Weir, W. C. S. and Bose, S. (2003) Rule-Based Software Tool to Specify the Manufacturing Process Parameters for a Countoured EB-PVD Coating on a PW4000 Second Stage Turbine Blade, in 27th Annual Cocoa Beach Conference on Advanced Ceramics and Composites: B: Ceramic Engineering and Science Proceedings, Volume 24, Issue 4 (eds W. M. Kriven and H.-T. Lin), John Wiley & Sons, Inc., Hoboken, NJ, USA. doi: 10.1002/9780470294826.ch75

Author Information

  1. 1

    Worcester Polytechnic Institute, Material Science and Manufacturing Engineering, Worcester, MA 01609 USA

  2. 2

    Pratt and Whitney, Turbine Module Center, East Hartford, CT 06473 USA

Publication History

  1. Published Online: 26 MAR 2008
  2. Published Print: 1 JAN 2003

ISBN Information

Print ISBN: 9780470375846

Online ISBN: 9780470294826

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Keywords:

  • manufacturing process;
  • thermal barrier coating;
  • partially stabilized zirconia;
  • theoretical model;
  • vapor cloud

Summary

A rule-based design software tool has been developed to specify the manufacturing process parameters to fabricate a contoured electron beam physical vapor deposited (EB-PVD) partially stabilized zirconia (PSZ) thermal barrier coating (TBC) on a PW4000 second stage turbine blade. The expert data for this tool was developed from model predictions based on an experimentally verified, theoretical model of coating deposition rates as a function of position in the PVD vapor cloud (Knudsen cosine law). The predictive model was used for a variety of process parameters to develop a database of contoured coating profiles (forward chaining). A coating profile matching routine was developed to identify the process parameters that yield a coating profile that matches the desired coating profile using a backward chaining technique. The focus of this paper will be on the software tool with emphasis on the expert database development and the coating thickness profile matching for a curved surface.