Gas turbine engines and methods associated therewith
A method of forming a gas turbine engine component, the method including forming a plurality of cooling apertures in a preform structure of the component, the plurality of cooling apertures of the preform structure comprising a first cooling aperture and a second cooling aperture, wherein cross-sectional shapes of the first and second cooling apertures of the preform structure are different from one another, as measured in a same relative plane; and applying a coating to at least a portion of the preform structure to form the component, wherein a cross-sectional shape of the first and second cooling apertures of the component are approximately the same as one another, as measured in the same relative plane.
1 . A gas turbine engine component comprising:
a preform structure defining a plurality of cooling apertures, the plurality of cooling apertures including a first cooling aperture and a second cooling aperture; and
a coating disposed over at least a portion of the preform structure;
wherein the first cooling aperture includes a first portion having a first slope profile and wherein the second cooling aperture includes a second portion having a second slope profile such that the first slope profile is different from the second slope profile with respect to a reference plane, and wherein the coating is disposed over the first portion and the second portion such that the first portion and the second portion have a same coating slope profile with respect to the reference plane.
2 . The gas turbine engine component of claim 1 , wherein the first slope profile differs from the second slope profile in at least one of: relative angle, relative depth, relative geometry, relative size, height, distance, angle, entry angle, scale factor, ratio of length to width at a defined depth, or surface features.
3 . The gas turbine engine component of claim 1 , wherein the coating creates uniformity of the first cooling aperture and the second cooling aperture.
4 . The gas turbine engine component of claim 1 , wherein the coating comprises at least one of a thermal barrier coating (TBC), a bond coating, and an environmental barrier coating.
5 . The gas turbine engine component of claim 1 , wherein the gas turbine engine component comprises a portion of a blade.
6 . The gas turbine engine component of claim 1 , wherein the first slope profile is a first height characteristic and the second slope profile is a second height.
7 . The gas turbine engine component of claim 6 , wherein the coating has an uneven thickness, and wherein the uneven thickness corresponds with a dispersion pattern used in applying the coating.
8 . The gas turbine engine component of claim 1 , wherein the preform structure is an additively manufactured preform structure.
9 . The gas turbine engine component of claim 1 , wherein the coating has an uneven thickness.
10 . The gas turbine engine component of claim 1 , wherein the first slope profile is an underlying surface of the preform structure for the first cooling aperture and second slope profile is an underlying surface of the preform structure for the second cooling aperture.
11 . The gas turbine engine component of claim 1 , wherein the coating is a plasma deposition coating or a direction coating.
12 . The gas turbine engine component of claim 11 , wherein directional coating is performed in a direction within a range between 25 degrees and 90 degrees with respect to a relative plane.
13 . A gas turbine engine component comprising:
a preform structure defining a plurality of cooling apertures, the plurality of cooling apertures including a first cooling aperture and a second cooling aperture, the preform structure for the first cooling aperture having a first slope profile and the preform structure for the second cooling aperture having a second slope profile, the first slope profile different from the second slope profile in a reference plane; and
a coating disposed over at least a portion of the preform structure, wherein the coating forms a same cooling slope profile in the reference plane for both the first cooling aperture and the second cooling aperture.
14 . The gas turbine engine component of claim 13 , wherein the coating forms a first outermost surface of the preform structure for the first cooling aperture and a second outermost surface of the preform structure for the second cooling aperture, and wherein the same cooling slope profile shares at least one of a common relative shape or size.
15 . The gas turbine engine component of claim 13 , wherein the first slope profile forms a first underlying surface of the preform structure for the first cooling aperture and the second slope profile forms a second underlying surface of the preform structure for the second cooling aperture.
16 . The gas turbine engine component of claim 15 , wherein the first underlying surface of the preform structure for the first cooling aperture and the second underlying surface of the preform structure for the second cooling aperture are offset to compensate for a dispersion pattern used in applying the coating.
17 . The gas turbine engine component of claim 15 , wherein the first underlying surface of the preform structure for the first cooling aperture differs from the second underlying surface of the preform structure for the second cooling aperture in at least one of distance, angle, relative depth, entry angle, scale factor, profile features, ratio of length to width at a defined depth, or a combination thereof.
18 . The gas turbine engine component of claim 13 wherein the preform structure is configured to accommodate for at least one of a spray intensity, a spray direction, minimum coating requirements.
19 . The gas turbine engine component of claim 13 , wherein the gas turbine engine component comprises a portion of a blade.
20 . The gas turbine engine component of claim 13 , wherein a cooling hole division is disposed between adjacent of the plurality of cooling apertures and an underlying surface of the preform structure for a first cooling hole division is different from an underlying surface of the preform structure for a second cooling hole division.