Surface treatment device

Abstract

A surface treatment device (10) is provided for applying a surface treatment medium to an article (60). The device comprises an application member (12, 14) for holding and applying the surface treatment medium to the article. The device has a securing arrangement (40) for securing the application member to the article.

Description

Embodiments of the invention will now be described by way of example only, with reference to the accompanying drawings, in which:

FIG. 1 is a diagrammatic view of a surface treatment device;

FIG. 2 is a diagrammatic view of a securing arrangement for securing the surface treatment device to an article;

FIG. 3 shows another embodiment of a surface treatment device;

FIG. 4 shows a sectional top view of a part of a surface treatment device;

FIG. 5 is a diagrammatic view of a support assembly for a surface treatment device;

FIG. 6 shows a further embodiment of a surface treatment device;

FIG. 7 shows another embodiment of a surface treatment device mounted on an article;

FIG. 8 shows surface treatment device including a securing arrangement;

FIG. 9 shows an embodiment of a securing arrangement;

FIG. 10 shows a surface treatment device mounted on an article;

FIG. 11 shows an article with a support assembly for a surface treatment device; and

FIG. 12 shows a further embodiment of a support assembly;

FIG. 13 is a diagrammatic view of a further embodiment of a surface treatment device;

FIG. 14 is a diagrammatic representation of a method of forming the surface treatment device shown in FIG. 13;

FIG. 15 is a perspective view of a fan blade;

FIG. 16 is a perspective view of the blade shown in FIG. 15 with a ceramic dispenser applied thereto;

FIG. 17 is a close up view of the dispenser shown in FIG. 16; and

FIG. 18 is a perspective view of the fan blade shown in FIG. 16 with a surface treatment device applied thereto;

FIG. 19 is a diagrammatic perspective view of a further embodiment of a surface treatment device;

FIG. 20 is a diagrammatic cross-section view of the embodiment shown in FIG. 19; and

FIG. 21 is a view of the region marked XXI in FIG. 20 after operation of a feature therein.

Referring to FIG. 1, there is shown a surface treatment device 10 in the form of a cassette comprising a first application member 12, and a second application member 14. The first and second application members 12, 14 are connected to one another at a pivot 16, and can pivotally move relative to one another as shown by the arrows X and Y.

A first portion of each of the first and second application members 12, 14 extends on one side of the pivot 16, and provides a holding portion 18 for a surface treatment medium 20. A second portion 21 of each of the first and second application members extends on the opposite side of the pivot 16 and provide reaction members 152 for springs to clamp the surface treatment device on articles as explained below in connection with FIG. 6.

Although the surface treatment medium 20 is seen only on the first application member 12, it will be appreciated that it will be provided also on the second holding portion of the application member 14.

A water soluble wax sealant 22 is provided around the edge regions of each of the holding portions 18. An inner liner 24, for example formed of a polypropylene material is provided around the inner edge of the sealant 22.

A paste 26 is held within the liner 24, and comprises a surface treatment medium in the form of an etching medium, to be applied to an article to be treated. The article may be, for example, a fan blade of a gas turbine engine. The etching medium 26 comprises hydrofluoric acid, nitric acid and a powder material, such as titanium dioxide to provide a paste to the desired thickness. The amounts of the acid and the powder can be adjusted to provide the desired thickness of the paste 26.

Mixing means 28 is provided in each of the first and second application members 12, 14 and comprises an elongate steel wire 30 as shown in broken lines, and a pair of magnets 32. The wire 30 extends across the holding portions 18 of the first and second application members 12, 14. The magnets 32 are connected to a suitable motor and can move up and down the application member as shown by the arrows A, B to move the metallic wire 30 also in the direction of the arrows A, B to stir the paste within the holding portions 18. The stirring of the paste provides the advantage in this embodiment that it helps to prevent the formation of electrochemically passivated regions, and/or regions where the paste is detached from the workpiece.

If desired, the holding portions 18 of the first and second application members 12, 14 can be provided with inlets 34 and outlets 36 to allow a liquid to pass into and out of the respective holding members 18. In an alternative embodiment, instead of the holding members holding a paste 20 of the etching medium, the holding members could hold the powdered material, and the etching, or other medium could be supplied to the respective holding portions 18 as desired. After the etching medium has been applied to the article, the etching medium could be flushed out by passing water into the holding portions 18 through the inlet apertures 34 and out of outlet apertures 36.

In order to secure the cassette 10 onto the article, a securing arrangement in the form of a clamp 40 is provided. The clamp 40 comprises first and second mounting members 42, 44 which are pivotally attached to each other at a pivot 46. Each of the clamping members 42, 44 comprises a first portion in the form of an engaging portion 48 extending on one side of the pivot. Engaging members 50 are provided on the free ends of the engaging portions 48.

A second portion, in the form of a reaction portion 52, of each of the first and second mounting members 42, 44 extends on the opposite side of the pivot 46 to the engaging portion 48.

The clamp 40 is arranged such that the engaging members 50 engage the holding portions 18 of the first and second application members 12, 14. The spring 54 urges the reaction portions inwardly, thereby urging the engaging portions inwardly to clamp the engaging members 50 onto the holding portion 18 of the first and second application members 12, 14. In this way, the surface treatment device 10 is secured to the article to be treated.

FIG. 3 shows a further embodiment of the cassette 10 in which a liquid medium is supplied to the holding portions 18 of the first application member 12 via the inlet apertures 34, as shown by the arrows C.

The liquid passes out of the first application member 12 via the outlet 36 to a waste tank 56 to enable the etching medium to be disposed of.

FIG. 4 shows a sectional top view of a further embodiment of a cassette 10 applied to a leading edge of a fan blade 60. An elongate wire 30 is provided in the paste 20 and around the leading edge of the fan blade 60. The pair of magnets 32 on each of the application members 12, 14, as shown in FIG. 1, is replaced by a single magnet 62 on each of the first and second application members 12, 14 and the elongate wire 30 is moved up and down by the up and down movement of the magnets 62.

FIG. 5 shows a support arrangement in the form of a jig 64 upon which one or more cassettes 10 can be mounted. The jig 64 comprises a main support member 66 and upper and lower subsidiary support members 68, 70. The cassette 10 is mounted on to the main support member 66 and held in place thereon by the clamp 40.

Referring to FIG. 6, there is shown a further embodiment of the cassette 10 and the same features have been designated with the same reference numerals. The operation of FIG. 6 differs from the embodiment shown in FIGS. 1 to 4 in that a ceramic inner dispenser 72 is provided. The ceramic dispenser 72 is formed of a porous ceramic material such as aluminosilicate.

The ceramic dispenser 72 is cast in-situ on the blade 60 by the use of a suitably configured forming tool. A release agent may be provided to prevent the dispenser 72 bonding either to the fan blade 60 or the forming tool. After the formation of the dispenser 72, the cassette 10 is then arranged over it, as shown in FIG. 6. As can be seen, the cassette 10 shown in FIG. 6 differs from the cassette 10 shown in FIG. 1, in that a separate clamp 40 is not required, because of the provision of rearwardly extending engagement members 152 which are engaged by a spring 154 to push the holding portions 18 to their closed position in which they are sealed against the fan blade 60.

As can be seen the dispensing device 10 shown in FIG. 6 also includes seals 22 and inner liners 24.

In use, when the cassette 10 is clamped over the dispenser 72, suitable etching medium can be provided through the inlet apertures 34 to pass through the dispenser on to the leading edge region of the fan blade to be treated.

The pivot 16 is of a tubular configuration and is hollow so that it can be fitted over a main support member of a support arrangement, such as a jig 64 shown in FIG. 5.

It will be appreciated by the skilled person that, in the embodiment shown in FIG. 6, the ceramic dispenser 72 could be replaced by a paste 20 as described in FIG. 1, or by a powder, to which the medium can be supplied. In such a case inert members 74 are provided to control the correct thickness of the paste 20. The inert members may be of a hemispherical configuration, and may be formed of a polymeric material.

The paste could be provided in a pack comprising two compartments, namely a first compartment holding an acid, and a second compartment holding titanium dioxide. The first and second compartments may be separated from each other by a seal or a membrane. The contents of both compartments can be mixed on breaking the seal or membrane. The seal or membrane can be formed of a polymeric material. Alternatively, the two compartments could be part of a pliable composite unit.

In another embodiment, the ceramic dispenser 72 could be replaced by a substrate on which the paste has already been provided. The cassette 10 would then press the substrate and the paste against the leading edge region of the fan blade to be treated. The embodiment involving the use of a substrate is described below.

Referring to FIGS. 7, 8 and 9, there is shown a further embodiment. FIG. 7 shows a cassette 10 applied to the leading edge region of a fan blade 60. The cassette 10 is held in place by clamps in the form of clips 80, an example of which is shown in FIG. 9. FIG. 8 shows the arrangement of the clips 80 on the cassette 10. As can be seen, elongate clips 80A alternate with shorter clips 80B to provide clamping across the width of each of the application members 12, 14.

Referring to FIG. 9, the clip 80 comprises a pair of clamping members 82 which engage the respective application member 12, 14, and a spring portion 84 formed of a suitable plastics material to urge the clamping members 82 in the direction shown by arrows D.

Referring to FIG. 10, there is shown a further embodiment, for clamping a cassette 10, similar to that shown in FIG. 7 to a leading edge of a fan blade 60. In the embodiment shown in FIG. 10, the clips 80 comprise a flanged portion 86 which provides the resilient urging of the clamping member 82 against the cassette 10.

A pivotal connection 88 is provided between connecting members 90 which extend from the clamping members 82 to the resilient portion 86 to allow different orientation of each of the clamping members 82. In addition to the gimble 80, hinged mounts 90 are provided to allow the clamping members 82 to further pivot. Guide rails 92, which extend from a support assembly 64 hold the clips 80 in place. Although FIG. 11 shows only three blades 60 on the disc 102, it will be appreciated by the skilled person that there would be an array of blades 65 conveyed one after the other circumferentially around the disc 102.

Referring to FIG. 11, there is shown a surface treatment assembly 100 comprising a cassette 10 which engages a fan blade 60. The fan blade 60 is integrally mounted on a disc 102 such that the combination of the blade 60 and the disc 102 is referred to in the art as a blisk. The cassette 10 is supported by a support assembly 104 which comprises a main elongate support member 106 supported by a triangular arrangement of subsidiary support members 108. The support assembly 104 is mounted at the central region 110 of the blisk 102.

The main support member 106 defines along its length a plurality of apertures 112, at which a respective one of the cassettes 10 can be mounted.

Referring to FIG. 12, there is shown an embodiment of a support assembly 104 which comprises a rectangular base member 120 and an upstanding carrying arrangement 110 comprising four elongate support members 112 arranged in a square configuration relative to one another. The provision of the square arrangement of the subsidiary support members 112 allows the support assembly 104 to be used for curved fan blades.

The support assembly 104 shown in FIG. 12 comprises front and rear guide members 122 which can support a clamp 40. The guide members 122 can be arranged at differing heights of the support members 112 thereby supporting the clamp 40 at different radial heights of the fan blade 60. A lid 124 is provided on the support members 112 to hold them rigidly in position.

Referring to FIGS. 13 and 14, there is shown a further embodiment of the surface treatment device 10, in which an etching medium in the form of a paste 20 is first applied to a substrate 130. The substrate 130 can be a metal foil of a tape of a plastics material.

The substrate 130 has spacers 132 thereon, which are in the form of hemispherical beads of plastics material. The spacers 132 provide a means to determine the correct depth of the paste 20.

The substrate 130 is of the correct size and shape to fit precisely over the area to be treated of the leading edge region of a fan blade 60.

In the embodiment shown in FIG. 13, the securing arrangement is in the form of tabs 134 which extend outwardly from a main part 136. The tabs 134 are coated with an adhesive to adhere the surface treatment device 10 shown in FIG. 13 to the leading edge region of the fan blade 60.

FIG. 14 shows a method for forming the surface treatment device 10 shown in FIG. 13.

A container 138 of an inert polymeric material is filled with the paste 20 of the etching medium. The substrate 130 is then arranged on the paste 20, and a roller 140 is rolled across the upper surface of the substrate 130. This causes the paste 20 to be coated onto the lower surface of the substrate 130 to the depth of the spacers 132. The substrate 130 can then be removed from the container 138 and folded to the correct shape of the region of the fan blade 60 to be treated.

Referring to FIGS. 15 to 18 there is shown a further embodiment. In FIG. 15 a fan blade 60 is shown. The fan blade 60 comprises a repair region 250, which is in requirement of surface treatment by an etching medium. A ceramic dispenser 252 is formed by slip casting around the repair region 250.

FIG. 17 shows a close up view of the ceramic dispenser 252 just after formation by slip casting. The ceramic dispenser 252 has a main part 254 which has been cast around a plurality of glass rods 256. After formation of the ceramic dispenser 252 in a dried, but not fired state, the glass rods 256 are removed so that the main portion 254 defines a plurality of cylindrical conduits extending therethrough. The drying could be carried out by the application of an infra-red radiation thereto or by convection heating.

In the dried state, the ceramic dispenser 252 is porous and allows liquid to pass through the ceramic material.

A surface treatment device 10, such as the surface treatment device 10 shown in FIG. 6 is then arranged over the ceramic dispenser 252 and clamped in position on the fan blade 60, as shown in FIG. 18. A supply 256 of a surface treatment medium is then arranged in fluid communication by a pipe arrangement 258 with the cassette 10. The surface treatment medium flows into the cylindrical conduits in the ceramic dispenser 252 and pass to the surface of the fan blade 60 for surface treatment thereof. After a pre-determined time, the surface treatment device 10 and the ceramic dispenser 252 can be removed.

Referring to FIGS. 19 to 21 there is shown a further embodiment of a surface treatment device 10 for applying a surface treatment medium to a blade 60. In this embodiment, a pair of mixing buttons 150 are provided to mix the surface treatment medium in the device.

The mixing buttons 150 are in the pliable polymeric glands and include bristles 152 on the inner surface thereof. The surface treatment device 10 has an internal width H that is determined by the viscosity of the surface treatment medium therein.

Each of the buttons 150 can be depressed to cause the surface to flow and thereby mix. FIG. 21 shows one of the buttons 150 having been depressed to effect the aforesaid mixing.

There is thus described an effective device for etching a repair on a leading edge of a fan blade which is environmentally friendly and inexpensive to use.

It is an advantage of the above described embodiments that they provide only localised treatment of a blade, and act in a fail safe manner. That is to say that the amount of material provided in the device will only act on the blade for a predetermined period of time and will not cause excessive damage if left unattended for a long period of time.

Various modifications can be made without departing from the scope of the invention. For example, the arrangement of the support members 108 shown in FIG. 11 need not be triangular.

Claims

1. A surface treatment device for applying a surface treatment medium to an article, the surface treatment device characterised by an application member for holding and applying the surface treatment medium to the article and a securing arrangement comprising a clamp having a clamp member for securing the application member to the article.

2. A surface treatment device according to claim 1 wherein the surface treatment medium comprises an acid etching medium.

3. A surface treatment device according to claim 1 wherein the surface treatment medium comprises nitric acid and/or hydrofluoric acid.

4. A surface treatment device according to claim 1 wherein the surface treatment device comprises first and second application members for applying the medium to first and second regions of the article, the first and second application members being generally opposite each other to apply the medium to first and second opposite sides of the article.

5. A surface treatment device according to claim 4 wherein the first and second application members are pivotally attached to one another to allow pivotal movement of the first and second application members relative to each other.

6. A surface treatment device according to claim 4 wherein the first and second treatment members are integrally fixed relative to one another.

7. A surface treatment device according to claim 1 wherein the securing arrangement comprises an urging member to urge the, or each, application member in to engagement with the article.

8. A surface treatment device according to claim 7 wherein the urging member comprises a spring.

9. A surface treatment device according to claim 7 wherein the urging member is connected to the first and second application members, each of the first and second application members comprising a holding portion, in which the surface treatment medium can be held.

10. A surface treatment device according to claim 9 wherein each of the first and second application members comprises a reaction member in engagement with the urging member to be moved by the urging member thereby moving the holding portion.

11. A surface treatment device according to claim 9 wherein the holding portion extends on one side of the pivot, and the reaction portion extends on the opposite side of the pivot.

12. A surface treatment device according to claim 11 wherein the clamp comprises first and second clamping members, each clamping member being provided to engage a respective one of the first and second application members.

13. A surface treatment device according to claim 12 wherein the urging member may be provided on the clamping arrangement.

14. A surface treatment device according to claim 1 wherein a mixing arrangement is provided in the, or each, application member to mix the medium, the mixing arrangement comprising an elongate element, extending across the first and second application members.

15. A surface treatment device according to claim 14 wherein a controller is provided to control movement of the elongate element.

16. A surface treatment device according to claim 15 wherein the controller comprises first and second magnets each arranged on a respective one of the first and second application members, the magnets being movable along the first and second application members, to move the elongate member therewith.

17. A surface treatment device according to claim 1 wherein the, or each, application member comprises a carrier to carry the medium.

18. A surface treatment device according to claim 17 wherein the carrier comprises titanium dioxide powder.

19. A surface treatment device according to claim 1 wherein the, or each of the first and second application members is provided with inlet apertures to allow a flow of the surface treatment medium therethrough.

20. A surface treatment device according to claim 1 wherein the, or each, application member includes a liner on which the surface treatment medium can be held.

21. A surface treatment device according to claim 1 wherein a seal is provided around an edge of the, or each, application member.

22. A surface treatment device according to claim 21 wherein the seal comprises a mouldable wax.

23. A surface treatment device according to claim 1 wherein the surface treatment device comprises a substrate in the form of a tape or a foil, a paste of the surface treatment medium is provided on the substrate.

24. A surface treatment device according to claim 23 wherein the substrate comprises a main portion and the securing arrangement comprises a plurality of tabs extending from the main portion, the tabs including an adhesive to adhere the surface treatment device to the article.

25. A surface treatment device according to claim 1 including a dispenser held by the, or each application member, the dispenser being formed on the article.

26. A surface treatment device according to claim 25 wherein the dispenser is formed of a ceramic material and defines passages therethrough for the surface treatment medium.

27. A surface treatment device according to claim 25 wherein the, or each, application member is arrangeable over the dispenser to hold the dispenser on the article, and the surface treatment medium is supplied to the dispenser, the ceramic material being porous to allow the surface treatment, medium to pass therethrough.

28. A surface treatment assembly comprising a surface treatment device according to claim 1, and a support arrangement for supporting the surface treatment device on an article.

29. A surface treatment device according to claim 1 including a mixing arrangement comprising a button on the application member, the button being depressable to cause a flow of the surface treatment medium, thereby mixing the surface treatment medium.

30. A surface treatment device according to claim 29 wherein the button comprises a flexible polymer material, and includes mixing members on the inner surface thereof to enhance the mixing.

31. A surface treatment device according to claim 29 comprising a pair of the aforesaid buttons arranged adjacent each other on the application member.

32. A surface treatment assembly according to claim 29 wherein the support arrangement comprises a jig, and includes a main support member for supporting the surface treatment device, and subsidiary support members to support the main support member.

33. A surface treatment assembly according to claim 32 wherein the main support member comprises an elongate member having a plurality of fixing formations thereon, and each of which a surface treatment device can be fixed.

34. A surface treatment assembly according to claim 33 wherein the support assembly comprises a base member mountable on the article, and a plurality of upwardly extending support members capable of supporting a clamp.

35. A surface treatment assembly according to claim 34 wherein each of the support members is in the form of a tubular member, and comprises a plurality of fixing portions at which the surface treatment device can be secured.

36. A surface treatment assembly according to claim 32 wherein guide members may be provided to guide the clamping member on to the surface treatment device.

37. A method of treating a surface comprising applying a surface treatment device as claimed in claim 1 to the article, allowing the surface treatment medium to treat the surface of the article via the surface treatment device.

38. A method according to claim 37 comprising providing a paste of the surface treatment medium, and disposing the paste in the surface treatment device for application to the article.

39. A method according to claim 38 wherein a pre-treatment medium is provided to the, or each, application member, the pre-treatment medium being a preconditioning medium, which is capable of reacting with a surface oxide layer.

40. A method assembly according to claim 39 wherein the first treatment, medium comprises a sodium hydroxide and sodium chromate solution.

41. A method according to claim 40 wherein after treatment with the pre-treatment medium, the pre-treatment medium is removed, by flushing the, or each, application member.

42. A method according to claim 39 wherein the treatment medium is supplied to the, or each, application member via inlet apertures.

43. A method according to claim 42 wherein the second treatment medium comprises an etching medium.

44. A method according to claim 39 wherein after the treatment medium has been applied to the article, the second treatment medium is removed by flushing the, or each, application member.

45. A method according to claim 37 wherein a paste comprising the surface treatment medium is applied to a substrate, the substrate being a tape or a foil.

46. A method according to claim 45 wherein the substrate comprises outwardly extending tabs upon which an adhesive is provided to adhere the surface treatment device to this article.

47. A method according to claim 38 wherein a dispenser is provided in which the surface treatment medium is held, the dispenser being formed of a ceramic material, is shaped to conform to the surface of the article to be treated.

48. A method according to claim 47 wherein the dispenser is cast in-situ.

49. A surface treatment assembly according to claim 47 wherein passage forming members are provided in the ceramic material to create passages for the medium.

50. A surface treatment assembly according to claim 49 wherein the passage forming members comprise rods.