Patent Application
20230314304
The present disclosure relates to assemblies, systems and methods of quality control and service inspection for metallic electro-mechanical components and, more particularly, to assemblies, systems and methods of quality control and service inspection for metallic electro-mechanical components (e.g., stator components) utilizing fluorescent agents.
In general, to protect electro-mechanical components from corrosion, a protective coating can be used as an applied sprayed barrier layer (e.g., paint). However, there is a risk of inadequate coating coverage (e.g., with spottiness of the applied layer). Therefore, quality control of coating coverage can be a challenge for various reasons (e.g., due to complex surface shapes, hard-to-see internal corners, small sizes of imperfectly coated areas (spottiness), etc.).
Another challenge is expected corrosion during operation due to harsh environments or the like. Thus, detection of operational corrosion can be needed for pro-active maintenance (e.g., replacement, repair, etc.) and/or optimization of a protective coating. However, accurate detection of operational corrosion can be a difficult task (e.g., due to poor contrast, limited visibility and access, and potential subjectivity of assessment, especially, at the beginning of a corrosion process).
The present disclosure provides assemblies for quality control and service inspection for metallic electro-mechanical components, and improved systems/methods of quality control and service inspection for metallic electro-mechanical components. More particularly, the present disclosure provides embodiments that may result in improved assemblies, systems and methods of quality control and service inspection for metallic electro-mechanical components (e.g., aircraft stator components) utilizing fluorescent agents.
The present disclosure provides for a coated assembly including a metallic electro-mechanical component having an outer surface; and a protective coating or a first added layer positioned proximal to the outer surface, the protective coating or the first added layer comprising a first fluorescent agent; and wherein the first fluorescent agent operates as bright contrast media under a light source to identify imperfect coating or coating degradation during service of the metallic electro-mechanical component.
In addition to one or more of the features described, or as an alternative to any of the foregoing embodiments, the protective coating is positioned on the outer surface, and the first added layer is positioned on the protective coating.
In addition to one or more of the features described, or as an alternative to any of the foregoing embodiments, the first added layer comprises the first fluorescent agent, and the protective coating is free of the first fluorescent agent.
In addition to one or more of the features described, or as an alternative to any of the foregoing embodiments, the protective coating is positioned on the outer surface, and the metallic electro-mechanical component is free of the first added layer, the protective coating comprising the first fluorescent agent.
In addition to one or more of the features described, or as an alternative to any of the foregoing embodiments, the protective coating comprises the first fluorescent agent, and the first added layer comprises a second fluorescent agent.
In addition to one or more of the features described, or as an alternative to any of the foregoing embodiments, the first added layer is positioned on the outer surface, and the protective coating is positioned on the first added layer, the first added layer comprising the first fluorescent agent.
In addition to one or more of the features described, or as an alternative to any of the foregoing embodiments, the protective coating comprises a second fluorescent agent.
In addition to one or more of the features described, or as an alternative to any of the foregoing embodiments, a second added layer is positioned on the protective coating, the second added layer comprising a second fluorescent agent.
In addition to one or more of the features described, or as an alternative to any of the foregoing embodiments, the protective coating comprises a third fluorescent agent.
In addition to one or more of the features described, or as an alternative to any of the foregoing embodiments, the metallic electro-mechanical component is a stator metallic component, and the first fluorescent agent is a dye or a pigment; and the outer surface defines a plurality of protrusions and recesses.
The present disclosure provides for an inspection method including providing a metallic electro-mechanical component having an outer surface; and positioning a protective coating or a first added layer proximal to the outer surface, the protective coating or the first added layer comprising a first fluorescent agent; and applying a light source onto the metallic electro-mechanical component, with the first fluorescent agent operating as bright contrast media under the light source to identify imperfect coating or coating degradation during service of the metallic electro-mechanical component.
In addition to one or more of the features described, or as an alternative to any of the foregoing embodiments, the protective coating is positioned on the outer surface, and the first added layer is positioned on the protective coating; and the first added layer comprises the first fluorescent agent, and the protective coating is free of the first fluorescent agent; and wherein by applying light via the light source to the component, areas of imperfect or degraded coating of the component show an indication of no reflection of light, in contrast with neighboring undamaged regions of the component having bright reflection from the first fluorescent agent, and the areas of no reflection indicate the location and size of imperfect or degraded coating to the component during service inspection.
In addition to one or more of the features described, or as an alternative to any of the foregoing embodiments, the protective coating is positioned on the outer surface, and the metallic electro-mechanical component is free of the first added layer, the protective coating comprising the first fluorescent agent; and wherein by applying light via the light source to the component, areas of imperfect or degraded coating of the component show an indication of no reflection of light, in contrast with neighboring undamaged regions of the component having bright reflection from the first fluorescent agent, and the areas of no reflection indicate the location and size of imperfect or degraded coating to the component during service inspection.
In addition to one or more of the features described, or as an alternative to any of the foregoing embodiments, the protective coating is positioned on the outer surface, and the first added layer is positioned on the protective coating; and the protective coating comprises the first fluorescent agent, and the first added layer comprises a second fluorescent agent; and wherein by applying light via the light source to the component, areas of imperfect or degraded coating of the component show an indication of no reflection of light, in contrast with neighboring undamaged regions of the component having bright reflection from the first or second fluorescent agents, and the areas of no reflection indicate the location and size of imperfect or degraded coating to the component during service inspection.
In addition to one or more of the features described, or as an alternative to any of the foregoing embodiments, the first added layer is positioned on the outer surface, and the protective coating is positioned on the first added layer, the first added layer comprising the first fluorescent agent; and wherein by applying light via the light source to the component, areas of spottiness of the protective coating show an indication of reflection from the first fluorescent agent of the first added layer, in contrast with neighboring protective coated regions of the component with no reflection from the first fluorescent agent, and the areas of reflection indicate the location and size of imperfections of the protective coating of the component during a quality control assessment.
In addition to one or more of the features described, or as an alternative to any of the foregoing embodiments, the first added layer is positioned on the outer surface, and the protective coating is positioned on the first added layer, the first added layer comprising the first fluorescent agent; and further comprising a second added layer positioned on the protective coating, the second added layer comprising a second fluorescent agent; and wherein by applying light via the light source to the component, areas of imperfect or degraded coating of the component show an indication of no reflection of light, in contrast with neighboring undamaged regions of the component having bright reflection from the first or second fluorescent agents, and the areas of no reflection indicate the location and size of imperfect or degraded coating to the component during service inspection.
In addition to one or more of the features described, or as an alternative to any of the foregoing embodiments, wherein the metallic electro-mechanical component is a stator metallic component, and the first fluorescent agent is a dye or a pigment; and the outer surface defines a plurality of protrusions and recesses.
The present disclosure provides for an inspection method including providing a metallic electro-mechanical component having an outer surface; and positioning an added layer on the outer surface, the added layer comprising a fluorescent agent; and applying a light source onto the added layer to determine if the added layer was applied uniformly; and re-apply the added layer on the outer surface if the added layer was determined to be not applied uniformly; and positioning a protective coating on the uniformly applied added layer; and applying a light source onto the metallic electro-mechanical component, with the fluorescent agent operating as bright contrast media under the light source to identify imperfect coating of the metallic electro-mechanical component.
In addition to one or more of the features described, or as an alternative to any of the foregoing embodiments, wherein by applying light via the light source to the component, areas of spottiness of the protective coating show an indication of reflection from the fluorescent agent of the added layer, in contrast with neighboring protective coated regions of the component with no reflection from the fluorescent agent, and the areas of reflection indicate the location and size of imperfections of the protective coating of the component during a quality control assessment.
In addition to one or more of the features described, or as an alternative to any of the foregoing embodiments, the metallic electro-mechanical component is a stator metallic component, and the fluorescent agent is a dye or a pigment; and the outer surface defines a plurality of protrusions and recesses.
The above described and other features are exemplified by the following figures and detailed description.
Any combination or permutation of embodiments is envisioned. Additional features, functions and applications of the disclosed assemblies, systems and methods of the present disclosure will be apparent from the description which follows, particularly when read in conjunction with the appended figures. All references listed in this disclosure are hereby incorporated by reference in their entireties.
The following figures are example embodiments wherein the like elements are numbered alike.
Features and aspects of embodiments are described below with reference to the accompanying drawings, in which elements are not necessarily depicted to scale.
Example embodiments of the present disclosure are further described with reference to the appended figures. It is to be noted that the various features, steps, and combinations of features/steps described below and illustrated in the figures can be arranged and organized differently to result in embodiments which are still within the scope of the present disclosure. To assist those of ordinary skill in the art in making and using the disclosed assemblies, systems and methods, reference is made to the appended figures, wherein:
The example embodiments disclosed herein are illustrative of assemblies for quality control and service inspection for metallic electro-mechanical components, and systems of the present disclosure and methods/techniques thereof. It should be understood, however, that the disclosed embodiments are merely examples of the present disclosure, which may be embodied in various forms. Therefore, details disclosed herein with reference to example assemblies for quality control and service inspection for metallic electro-mechanical components and associated processes/techniques of fabrication/assembly and use are not to be interpreted as limiting, but merely as the basis for teaching one skilled in the art how to make and use the assemblies/systems and/or alternative assemblies/systems of the present disclosure.
The present disclosure provides assemblies, systems and methods of quality control and service inspection for metallic electro-mechanical components.
More particularly, the present disclosure provides assemblies, systems and methods of quality control and service inspection for metallic electro-mechanical components (e.g., aircraft metallic stator components) utilizing fluorescent agents.
Current practice provides that a protective coating (e.g., applied sprayed barrier layer) can be used to attempt to protect electro-mechanical components from corrosion; however, quality control of coating coverage can be a challenge for various reasons as discussed above. Moreover, detection of operational corrosion can be needed for pro-active maintenance and/or optimization of a protective coating but accurate detection of such corrosion can be a difficult task.
The present disclosure provides both (i) surface/assembly designs, and (ii) methods of their inspection. In example embodiments of the present disclosure, fluorescent agents can be mixed with protective and/or added layers to serve as bright contrast media under a light source (e.g., ultraviolet (“UV”) light source). It is noted that in a case of imperfect coating or coating degraded during service (e.g., due to corrosion), gaps in fluorescent reflection can serve as clear indications of either inadequate quality or excessive corrosion-driven degradation of the components.
The component 10 includes a protective coating 12 positioned on a surface 11 (e.g., outer surface 11) of the component 10. It is noted that surface 11 of component 10 can include or define protrusions 13 and/or recesses 15, with protective coating 12 positioned on the protrusions 13 and/or recesses 15 defined by surface 11.
As depicted in
As shown in
With reference again to
In regards to a system and method for service inspection for metallic electro-mechanical components 10 (e.g., a metallic stator component 10 or the like) and with continued reference to
As described above and with reference now to
With continued reference to
In regards to a system and method for quality control for metallic electro-mechanical components 10 (e.g., quality control for new, repaired and/or un-serviced components 10) and with continued reference to
In example embodiments for a system and method for quality control for components 10, it is noted that in a first step, the component 10 can be covered first with layer 22, the added layer 22 including a fluorescent agent. In a next step, by applying light (e.g., UV light via source 18) to the component 10 with layer 22, a user can check if the reflection of layer 22 is uniform. Layer 22 can be re-applied until it is uniformly applied, via checking with applying light via source 18. After layer 22 is uniformly applied, then coating 12 can be applied to layer 22. After this step, by applying light (e.g., UV light via source 18) to the component 10 with layer 22 and coating 12, a user can check if the there is still reflections of layer 22, with reflection areas of layer 22 indicating missed areas of coating 12. Coating 12 can be re-applied until it is uniformly applied (e.g., via an automated device), via checking with applying light via source 18.
With continued reference to
As depicted in
In a system and method for quality control for components 10 (e.g., quality control for new, repaired and/or un-serviced components 10) and with continued reference to
With continued reference to
Some example fluorescent agents for layers 14, 22 and/or coating 112 include, without limitation, dyes and/or pigments.
For example, fluorescent agents and/or dyes that absorb UV light (e.g., around 350 nm) and fluoresce in the visible spectrum can be utilized (e.g., added in the polymer composite resins and/or fibers of layers 14, 22 and/or coating 112).
Some example fluorescent agents include, without limitation: anthrathioxanthene, thioxanthene benzanthrone or anthraquinone series based chemistries. One example has the following molecular formula:
These family of colorants are known under the trade names Solvent Orange 63, Fluorescent Red GG, Hostasol Red GG, or Macolox Fluorescent Red GG.
In other example embodiments, xanthene, benzothioxanthene-dicarboximide, and aminoketones series-based chemistries can be utilized. Examples have the following molecular formulae:
These family of colorant(s) are known under the trade names Solvent yellow 98, Fluorescent YELLOW 3GF, Hostasol Yellow 3G, Solvent Fluorescent Yellow 3G, Rosaplast Yellow FSG, Keyplast Fluorecent Yellow 3R, RADGLo CFS-6-03 RED or Solvent Red 49.
Other examples include coumarin, coumarin 480, hydroxycoumarin, and glycidyl-oxycoumarin of the molecular formulae below:
These chemistries upon UV excitation fluoresce in the blue range of the visible spectrum (e.g., 400 to 500 nm).
Another example includes benzopyran based chemistry. One example has the following molecular formula:
This colorant is known under the trade name RADGLO CFS-6-02 RED, and Solvent Red 196.
Another example is azomethine based chemistry. One example has the following molecular formula:
This colorant is known under the trade name RADGLO VSF-0-01 Yellow. Upon UV excitation, it fluoresces in yellow/green color.
Other examples include naphthalimide and perylene based chemistries. Examples have the following molecular formulae:
These colorants are known under the trade name RADGLO CFS-0-01 Yellow or Solvent Yellow 43, RADGLO CFS-0-05 or Solvent Green 5. Upon UV excitation, it fluoresces in yellow/green color.
Some various UV fluorescent thermoset resin pigments under several commercial names can be utilized, such as, for example: (i) RADGLO® P-09 UV Blue pigment (solid solution of dyestuffs in a thermoset sulphonamide-melamine-paraformaldehyde polymer resin); (ii) RADGLO GM family of dyed/pigmented (range of colors) thermoset modified benzoguanamine-formaldehyde copolymer; (iii) RADGLO GRT family of dyed/pigmented (range of colors) thermoset polyester amide copolymers; and/or (iv) RADGLO PC and RADGLO PS families of dyed/pigmented (range of colors) thermoset sulphonamide-melamine-paraformaldehyde polymer resin.
There are many benefits of the assemblies, systems and methods of the present disclosure, including, without limitation: high reliability of detection of inadequate quality or excessive corrosion degradation; efficiency (convenience and robustness) of implementation; low cost and low demand of specially trained labor; opportunity to apply it as express method for coating optimization and/or benchmarking; opportunity to use available fluorescent agents; and/or the opportunity to utilize with both aircraft and non-aircraft components.
While particular embodiments have been described, alternatives, modifications, variations, improvements, and substantial equivalents that are or may be presently unforeseen may arise to applicants or others skilled in the art. Accordingly, the appended claims as filed and as they may be amended are intended to embrace all such alternatives, modifications variations, improvements, and substantial equivalents.
The ranges disclosed herein are inclusive of the endpoints, and the endpoints are independently combinable with each other (e.g., ranges of “up to 25 wt. %, or, more specifically, 5 wt. % to 20 wt. %”, is inclusive of the endpoints and all intermediate values of the ranges of “5 wt. % to 25 wt. %,” etc.). “Combinations” is inclusive of blends, mixtures, alloys, reaction products, and the like. The terms “first,” “second,” and the like, do not denote any order, quantity, or importance, but rather are used to distinguish one element from another. The terms “a” and “an” and “the” do not denote a limitation of quantity and are to be construed to cover both the singular and the plural, unless otherwise indicated herein or clearly contradicted by context. “Or” means “and/or” unless clearly stated otherwise. Reference throughout the specification to “some embodiments”, “an embodiment”, and so forth, means that a particular element described in connection with the embodiment is included in at least one embodiment described herein, and may or may not be present in other embodiments. In addition, it is to be understood that the described elements may be combined in any suitable manner in the various embodiments. A “combination thereof” is open and includes any combination comprising at least one of the listed components or properties optionally together with a like or equivalent component or property not listed.
Unless defined otherwise, technical and scientific terms used herein have the same meaning as is commonly understood by one of skill in the art to which this application belongs. All cited patents, patent applications, and other references are incorporated herein by reference in their entirety. However, if a term in the present application contradicts or conflicts with a term in the incorporated reference, the term from the present application takes precedence over the conflicting term from the incorporated reference.
Although the systems and methods of the present disclosure have been described with reference to example embodiments thereof, the present disclosure is not limited to such example embodiments and/or implementations. Rather, the systems and methods of the present disclosure are susceptible to many implementations and applications, as will be readily apparent to persons skilled in the art from the disclosure hereof. The present disclosure expressly encompasses such modifications, enhancements and/or variations of the disclosed embodiments. Since many changes could be made in the above construction and many widely different embodiments of this disclosure could be made without departing from the scope thereof, it is intended that all matter contained in the drawings and specification shall be interpreted as illustrative and not in a limiting sense. Additional modifications, changes, and substitutions are intended in the foregoing disclosure. Accordingly, it is appropriate that the appended claims be construed broadly and in a manner consistent with the scope of the disclosure.
