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The technology used in most modern industrial gas turbine (IGT) energy systems is a derivative of process technology that has been used in the aircraft engine industry for decades. Progressive Surface is uniquely qualified to provide systems to the IGT market due to its engineering expertise with the handling of large complex components and experience with the surface preparation requirements of advanced aircraft engines.

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Robotic shot peening IGT rotor and shaft hardware

Today's industrial gas turbine (IGT) engines are quite large with some of the rotor and shaft components larger than 8 ft in diameter and weighing more than 10,000 lbs. These very large components have many intricate features such as holes and dovetail slots which must be accessed to effectively shot peen. Progressive Surface's process experience and design knowledge allow for the right material handling solution to be offered as well as assuring all processing requirements are achieved.

Progressive Surface energy application - Robotic shot peening IGT rotor and shaft hardware

Thermal spray coating solid oxide fuel cell components

A solid oxide fuel cell (SOFC) is an electrochemical conversion device that produces electricity directly from fuel. These cells have a complex structure made up of three thermal sprayed coatings over a ceramic substrate. There are currently many different methods for applying these coatings in the SOFC manufacture including vacuum plasma spraying and thermal plasma CVD, however these methods can be cost prohibitive in a production environment. Progressive Surface has been working with a major SOFC supplier for nearly 7 years to provide air plasma sprayed coatings with an emphasis toward high quality coatings at lower total manufacturing cost.

Each of the manufacturing cells produced by Progressive Surface include a closed loop control system for running the entire plasma spray process. All key process parameters are measured and controlled to exact recipe parameters to ensure the as-sprayed coatings yield their proper electro/chemical properties. In addition, material handling, masking and part cooling are all integrated components within each manufacturing cell to help ensure maximum productivity.

Progressive Surface energy application - Thermal spray coating solid oxide fuel cell components

High-pressure turbine bucket and nozzle abrasive grit blast

Many industrial gas turbine (IGT) engine components are coated to improve performance, especially those found in combustor and turbine sections. Prior to thermal spray coating, the surfaces to be coated are prepared by abrasive blasting. Progressive Surface has designed a line of rotary index sand blasting systems to efficiently and effectively process these components. Turbine blades and nozzles can be quite large and have complex surfaces which need complete uniform blasting. The Progressive Surface system design is robust enough to withstand the harsh blasting environment, provide ergonomic part loading and fixturing, and offer many different process control options.

Progressive Surface energy application - High-pressure turbine bucket and nozzle abrasive grit blast

Coating densification and smoothing utilizing large peening media and Gravity Accelerated Shot Peening (GASP) process

The Progressive Surface patented Gravity Accelerated Shot Peening (GASP) process is a unique surface enhancement process. The media does not receive its energy from either compressed air or centrifugal wheels, but rather is accelerated by the gravitational force. Due to the large size media, high compressive stress is achievable and the resulting surface finish is very smooth. This unique process is used to shot peen large airfoil components where resulting surface finish is critical as well as used to densify.

Progressive Surface energy application - Coating densification and smoothing utilizing large peening media and Gravity Accelerated Shot Peening (GASP) process

100HE® dense thermal barrier coatings

One of the newest technologies introduced to Industrial Gas Turbines (IGTs) is the application of dense thermal barrier coatings (TBC) to turbine nozzles and buckets. The application of these dense TBCs is difficult for conventional plasma torches and users struggle to maintain the proper coating density without sacrificing coating application efficiency. Progressive's 100HE high enthalpy plasma torch offers superior plasma coating quality at unprecedented coating spray rates and deposit efficiencies while spraying these dense TBC coatings. In addition, the 100HE has a very wide process range that allows it to outperform conventional plasma spray systems for just about every material that is applied with the plasma process. thermal sprayed coatings to improve their performance.

Progressive Surface energy application - 100HE dense thermal barrier coatings

Grit blast industrial gas turbine transition pieces

Due to their large size and complex geometries, IGT Transition Pieces (TPs) are often times grit blasted manually. Progressive Surface has developed an automated alternative that incorporates a long lance on the end of a robotic manipulator. Special part holding tooling can also be included that enables automatic part flipping so that complete coverage can be achieved in a single cycle. Surface finish is kept consistent by 100% classification of reclaimed grit. TPs generally have long cycle times and the automated approach enables the operator to be utilized in other production areas.

Progressive Surface energy application - Grit blast industrial gas turbine transition pieces

Progressive Surface energy application - Grit blast industrial gas turbine transition pieces


IGT turbine blade root peening, lean cell

For each stage of the turbine section of a gas turbine, there can be 35 to over 100 individual blades that must be processed for new manufacture and overhaul. Progressive Surface offers a unique cell that quickly peens individual blade roots while another blade is made ready to enter the cell. When the peening process is complete on the first blade, a quick exchange is made and the second blade begins its processing. Three pressure blast nozzles ensure that each of the root's pressure faces receive direct impingement and efficient energy transfer from the peening media.

Progressive Surface energy application - IGT turbine blade root peening, lean cell