Motion planning for coating process optimisation in electron beam physical vapour deposition

S. Cho, I. Fuke, Vittaldas V. Prabhu

Research output: Contribution to journalArticle

5 Citations (Scopus)

Abstract

Electron beam physical vapour deposition (EB-PVD) is used mainly in a variety of coating and surface engineering applications. The present research focuses on coating process optimisation using EB-PVD for turbine blades, which are widely used in industrial, marine and aircraft applications. More specifically, the present research identifies the five most important objectives for the EB-PVD coating process and then proposes metrics to quantify such objectives. In addition, a heuristic for EFB-PVD process optimisation is developed to control workpiece motion systematically to reduce coating thickness variance, providing a uniform coating for turbine blades. The heuristic developed is an iterative algorithm which uses a finite element model of the rotating workpiece to determine the translation motion. The finite element model can be readily generated using standard computer aided design (CAD) of the workpiece, which makes the method applicable to workpieces with complex three-dimensional geometry. These computational developments are illustrated using a simulation of a turbine blade coating in which the coating thickness variance is reduced significantly. The proposed method could eliminate dedicated tooling/fixtures used in the traditional coating process and improve the cost effectiveness of the process, especially for low volume production.

Original languageEnglish (US)
Pages (from-to)279-289
Number of pages11
JournalSurface Engineering
Volume21
Issue number4
DOIs
StatePublished - Aug 1 2005

Fingerprint

Physical vapor deposition
Motion planning
planning
coating
Electron beams
vapor deposition
turbine blades
electron beams
coatings
Coatings
optimization
Turbomachine blades
Turbines
tooling
cost effectiveness
fixtures
computer aided design
aircraft
engineering
Motion control

All Science Journal Classification (ASJC) codes

  • Condensed Matter Physics
  • Surfaces and Interfaces
  • Surfaces, Coatings and Films
  • Materials Chemistry

Cite this

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Motion planning for coating process optimisation in electron beam physical vapour deposition. / Cho, S.; Fuke, I.; Prabhu, Vittaldas V.

In: Surface Engineering, Vol. 21, No. 4, 01.08.2005, p. 279-289.

Research output: Contribution to journalArticle

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