Innovative Methods for Automated Controlled Removal of Thermal Barrier Coatings (TBCs) and Bondcoats from Turbine Airfoils for Rework and Repair

This Phase II program seeks to develop a laser process for removing thermal barrier coatings (TBC) from engine airfoils for rework or repair. The TBC removal processing will be able to fully remove the TBC coating from the airfoil without excessive damage to or unwanted removal of the bond coat or base metal. The stripping process will not alter cooling holes geometry or shape. The laser removal process will targeted to be quicker and more cost effective than the current means of TBC stripping. This program will aid a number of Air Force engine components and technologies through cost reduction from reduced part waste and by extending the life cycle on existing parts. This program includes optimization of the stripping process with incorporation of robotic parts movement so that an automated TBC stripping cell work station will be developed. The technology will be demonstrated on a set coating system and airfoil in cooperation with an Air Force Prime Contractor. BENEFIT: The technology developments will reduce the cost associated with TBC removal and rework. The technology will allow for targeted removal with less part scrappage from damaging the bond coating or base metal airfoil during stripping. The stripping technology will aid in sustainment of a number of engine system on both military and commercial aircraft. Dual uses are expected as the similar coating issues are experienced by both commercial and military applications