Laser net shape manufacturing and repair using a medial axis toolpath deposition method

a technology of toolpath deposition and laser net, which is applied in the direction of manufacturing tools, soldering devices, turbines, etc., can solve the problems of rejecting and scrapping the entire, reducing the number of lack of fusion imperfections in the solid deposit, and reducing the cost of final product production.

Inactive Publication Date: 2008-07-31
GENERAL ELECTRIC CO
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  • Summary
  • Abstract
  • Description
  • Claims
  • Application Information

AI Technical Summary

Benefits of technology

[0016]The disclosed invention presents many advantages over the prior art method of layered deposition. By depositing a bead width al...

Problems solved by technology

The final product is expensive to produce, as it requires extensive high-precision machining operations.
An error in machining even one of the blades may result in rejection and scrapping of the entire BLISK or it may require an expensive and time consuming repair to render the part useable.
While this repair method is suitable for minor airfoil edge damage, it is not acceptable for more significantly damaged areas due to imbalance problems and potential mechanical property degradation.
Replacement or repair of a damaged blade portion of the BLISK presents a difficult problem with this cast and machine approach.
If all or a portion of a blade breaks off from impact of a foreign ...

Method used

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  • Laser net shape manufacturing and repair using a medial axis toolpath deposition method
  • Laser net shape manufacturing and repair using a medial axis toolpath deposition method
  • Laser net shape manufacturing and repair using a medial axis toolpath deposition method

Examples

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Embodiment Construction

[0026]In Laser Net Shape Manufacturing (LNSM), the dimensions and overall geometry of the repair are rendered in accordance with a computer-aided design (CAD) description. The geometry of the repair must be described mathematically. Modeling of the shapes is achieved through the use of a CAD system, and from these representations, tool paths are generated to drive the LNSM process.

[0027]A CAD model of a part to be fabricated or repaired is generated by numerically characterizing the shape of the article such as a blade from drawings or a part prepared by more conventional methods such as machining. Once the shape of the part is numerically characterized, the computer generates a series of uniform slices along the desired direction of material buildup, and the computer determines a medial axis or spine (hereinafter referred to as a medial axis) for each slice. Based on a predetermined width of a bead of deposited material, it may be necessary to apply more than one pass of material i...

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Abstract

A method is disclosed for laser net shape manufacturing a part or repairing an area of a part comprising providing a CAD model of the part to be manufactured or repaired, digitally slicing the CAD model into a plurality of deposition layers, determining a medial axis for each of the deposition layers of the part or repair area; and depositing a bead of a material in a pattern centered upon the medial axis of each of the deposition layers so as to build-up the material by each of the deposition layer until the part is manufactured or repaired.

Description

FIELD OF THE INVENTION[0001]This invention relates to laser cladding method for fabricating or repairing a part, such as a BLISK, compressor blade or compressor component.BACKGROUND OF THE INVENTION[0002]An aircraft gas turbine engine or jet engine draws in and compresses air with an axial flow compressor, mixes the compressed air with fuel, burns the mixture and expels the combustion gases through an axial flow turbine that powers the compressor. The compressor includes a disk with blades projecting from its periphery. The disk turns rapidly on a shaft, and the curved blades draw in and compress air.[0003]In current manufacturing practice, the compressor is made by forging the compressor disk as a single piece with slots at the periphery. The compressor blades are individually forged or cast to shape with a root section termed a dovetail that fits into slots formed in the disk. Assembly is completed by sliding the dovetail sections of the blades into the slots in the disk. If a bla...

Claims

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Application Information

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IPC IPC(8): C23C26/00
CPCB22F3/1055B22F5/04B23K26/34B23P6/007B23P15/02C23C26/02B23K35/0244F01D5/34F04D29/023F04D29/324F05D2230/80F05D2230/31B23K35/0238F01D5/005Y02P10/25B22F10/25
Inventor SINGH, PRABHJOTQI, HUANAZER, MAGDI NAIMKULKARNI, PRASHANT MADHUKAR
Owner GENERAL ELECTRIC CO
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