Inspection and repair tools

Abstract

A method for inspecting and repairing the surface of a component of a gas turbine engine, the method comprising: inserting an inspection and repair tool into the interior of the gas turbine engine; inspecting the surface of the component using the inspection and repair tool; repairing the surface of the component from the interior of the gas turbine engine using the inspection and repair tool, wherein the inspection and repair tool remains inside the gas turbine engine between inspecting the component and repairing the surface of the component.

Description

Technical Field

[0001] The present subject matter generally relates to inspection and repair tools used within gas turbine engines and methods of using the same. Background Art

[0002] The use of thermal barrier coatings (TBCs) on components such as combustors, high pressure turbine (HPT) blades, vanes and shrouds helps such components survive higher operating temperatures, increasing component durability and improving engine reliability. TBCs are typically formed from ceramic materials and deposited on an environmentally friendly bond coat to form a so-called TBC system.

[0003] Under operating conditions, hot section engine components protected by the TBC system are susceptible to various modes of damage including erosion, oxidation and corrosion due to exposure to gaseous products of combustion, foreign object damage (FOD), and attack from environmental contaminants. The source of environmental contaminants is the ambient air, which the engine draws in for cooling and combustion purposes. The types of environmental contaminants in the ambient air will vary from location to location but may be of concern to aircraft since they are intended to move from one location to another. These environmental contaminants are in addition to the corrosive and oxidizing contaminants produced by the combustion of the fuel.

[0004] Some of these contaminants may result in loss of TBC over the life of the component, leaving a small portion of the TBC or completely removing a portion of the TBC, exposing the underlying component to operating conditions and potentially damaging the component.

[0005] Therefore, methods and systems for repairing TBCs would be useful. Summary of the invention

[0006] Aspects and advantages of the invention will be set forth in part in the following description, or may be obvious from the description, or may be learned through practice of the invention.

[0007] Aspects of the present disclosure relate to a method for inspecting and repairing a surface of a component of a gas turbine engine. The method includes: inserting an inspection and repair tool into the interior of the gas turbine engine; inspecting the surface of the component using the inspection and repair tool; and repairing the surface of the component from the interior of the gas turbine engine using the inspection and repair tool, wherein the inspection and repair tool remains inside the gas turbine engine between inspecting the component and repairing the surface of the component.

[0008] These and other features, aspects and advantages of the present invention will be better understood with reference to the following description and appended claims.The accompanying drawings, which are incorporated in and constitute a part of this specification, illustrate embodiments of the present invention and, together with the description, serve to explain the principles of the present invention. BRIEF DESCRIPTION OF THE DRAWINGS

[0009] A full and enabling disclosure of the invention, including the best mode thereof, to one of ordinary skill in the art is set forth in the specification, which refers to the accompanying drawings, in which:

[0010] Figure 1 is a schematic cross-sectional view of an exemplary gas turbine engine according to various embodiments of the present subject matter;

[0011] Figure 2 is a perspective cross-sectional view of a combustor assembly having a damaged TBC according to an exemplary embodiment of the present disclosure;

[0012] Figure 3 is a schematic diagram of a system for in-situ inspection and repair of a portion of a thermal barrier coating of a component according to an exemplary embodiment of the present disclosure;

[0013] Figure 4 is another schematic diagram of a system for in-situ inspection and repair of a portion of a thermal barrier coating of a component according to an exemplary embodiment of the present disclosure;

[0014] Figure 5 is a close-up perspective view of a distal end of an inspection and repair tool with a spray head in a first position according to an exemplary embodiment of the present disclosure;

[0015] Figure 6 is a photo of a thermal barrier coating that needs repair;

[0016] Figure 7 yes Figure 5 A close-up perspective view of a distal end of the inspection and repair tool with the spray head in a second position;

[0017] Figure 8 is a flow chart of a method for inspecting and repairing a thermal barrier coating of a component of a gas turbine engine according to an exemplary aspect of the present disclosure.

[0018] Repeat use of reference characters in the present specification and drawings is intended to represent same or analogous features or elements of the invention. DETAILED DESCRIPTION

[0019] Reference will now be made in detail to the present embodiments of the present invention, one or more examples of which are shown in the accompanying drawings. The detailed description uses numerical and letter designations to refer to features in the drawings. The same or similar designations have been used to refer to the same or similar parts of the present invention in the drawings and description.

[0020] The word “exemplary” is used herein to mean “serving as an example, instance, or illustration.” Any implementation described herein as “exemplary” is not necessarily to be construed as preferred or advantageous over other implementations.

[0021] As used herein, the terms “first,” “second,” and “third” may be used interchangeably to distinguish one component from another, and are not intended to indicate the position or importance of the respective components.

[0022] The terms "forward" and "aft" refer to relative positions within a gas turbine engine or vehicle and refer to the normal operating attitude of the gas turbine engine or vehicle. For example, for a gas turbine engine, forward refers to a position closer to the engine inlet, while aft refers to a position closer to the engine nozzle or exhaust.

[0023] The terms "upstream" and "downstream" refer to relative directions relative to the flow of a fluid in a fluid path. For example, "upstream" refers to the direction from which the fluid is flowing, while "downstream" refers to the direction toward which the fluid is flowing.

[0024] Unless otherwise indicated herein, the terms "coupled," "fixed," "attached to," and the like refer to both direct coupling, fixing, or attachment as well as indirect coupling, fixing, or attachment through one or more intermediate components or features.

[0025] The term "repair" with respect to a component generally refers to any repair or maintenance activity on such a component, including any activity that adds material to a component, removes material from a component, or changes the material properties of all or part of a component. In at least some embodiments, the term "repair" with respect to a component refers to performing tasks associated with rejuvenating damaged portions of a component and maintaining or protecting damaged and undamaged portions of a component.

[0026] The singular forms "a", "an" and "the" include plural forms unless the context clearly dictates otherwise.

[0027] As used herein throughout the specification and claims, approximating language is used to modify any quantitative representation that can be permissibly varied without resulting in a change in the basic function to which it is related. Thus, values ​​modified by terms such as "about," "approximately," and "substantially" are not limited to the precise values ​​specified. In at least some cases, approximate language may correspond to the precision of an instrument used to measure a value, or the precision of a method or machine used to construct or manufacture a component and / or system. For example, approximate language may refer to within 10%.

[0028] Here and throughout the specification and claims, range limitations are combined and interchanged, and unless context or language indicates otherwise, such ranges are identified and include all sub-ranges contained therein. For example, all ranges disclosed herein include the endpoints, and the endpoints are independently combinable with each other.

[0029] It will be appreciated that in order to repair damaged areas of the thermal barrier coating ("TBC"), one or more inspection operations will typically need to be performed manually using, for example, a borescope inspection tool. During the inspection operations, any areas requiring repair may be noted. Subsequently, the engine may be "off wing" (i.e., removed from the aircraft), components may be removed (or the engine may be disassembled to expose the components), the areas requiring repair may be cleaned, a thermal barrier coating repair may be applied and cured, and the components may be reinstalled and the engine reinstalled on the aircraft.

[0030] This is a relatively time consuming and expensive process. In view of the above, it will be appreciated that it would be desirable if systems and methods were available for repairing and inspecting thermal barrier coatings that did not require multiple different tools and did not require the engine to be removed from the wing and at least partially disassembled.

[0031] Thus, aspects of the present disclosure provide systems and methods for repairing a surface of a component of a gas turbine engine, such as a TBC of a component of a gas turbine engine.The systems and methods described herein may facilitate in-situ inspection and repair of a TBC or other aspects of a component.

[0032] In at least one exemplary aspect, the method may include inserting an inspection and repair tool into the interior of a gas turbine engine; inspecting a surface of a component using the inspection and repair tool; and performing repairs on the surface of the component from the interior of the gas turbine engine using the inspection and repair tool. In this manner, it will be appreciated that the inspection and repair tool remains inside the gas turbine engine between inspecting the component and performing repairs on the surface of the component. This can effectively result in a more compact inspection and repair process using the inspection and repair tool compared to conventional inspection and repair processes, thereby saving time and cost. More specifically, by using a tool capable of performing both inspection and repair processes, the total time to perform these operations and the amount of time the engine is out of service can be reduced.

[0033] Now referring to the accompanying drawings, Figure 1 is a schematic cross-sectional view of a gas turbine engine according to an exemplary embodiment of the present disclosure. More particularly, Figure 1 In the embodiment of the present invention, the gas turbine engine is a high bypass turbofan jet engine 10, referred to herein as a "turbofan engine 10". Figure 1 As shown, the turbofan engine 10 defines an axial direction A (extending parallel to a longitudinal centerline 12 for reference) and a radial direction R. Generally, the turbofan engine 10 includes a fan section 14 and a core turbine engine 16 disposed downstream of the fan section 14 .

[0034] The illustrated exemplary core turbine engine 16 generally includes a substantially tubular casing 18 defining an annular inlet 20. The casing 18 encloses, in serial flow relationship: a compressor section including a supercharger or low pressure (LP) compressor 22 and a high pressure (HP) compressor 24; a combustion section 26; a turbine section including a high pressure (HP) turbine 28 and a low pressure (LP) turbine 30; and an ejection exhaust nozzle section 32. A high pressure (HP) shaft or spool 34 drivingly connects the HP turbine 28 to the HP compressor 24. A low pressure (LP) shaft or spool 36 drivingly connects the LP turbine 30 to the LP compressor 22.

[0035] For the illustrated embodiment, the fan section 14 includes a variable pitch fan 38 having a plurality of fan blades 40 coupled to a disk 42 in a spaced apart manner. As shown, the fan blades 40 generally extend outwardly from the disk 42 in a radial direction R. Each fan blade 40 is rotatable about a pitch axis P relative to the disk 42 by virtue of the fan blades 40 being operably coupled to a suitable actuation member 44, which is configured to collectively and uniformly change the pitch of the fan blades 40. The fan blades 40, the disk 42, and the actuation members 44 together are rotatable about the longitudinal axis 12 via the LP shaft 36 across an optional power gearbox 46. The power gearbox 46 includes a plurality of gears for reducing the rotational speed of the LP shaft 36 to a more efficient rotating fan speed.

[0036] Still reference Figure 1 In an exemplary embodiment of the present invention, the disk 42 is covered by a rotatable forward nacelle 48 that is aerodynamically shaped to facilitate airflow through the plurality of fan blades 40. In addition, the exemplary fan section 14 includes an annular fan case or outer nacelle 50 that circumferentially surrounds the fan 38 and / or at least a portion of the core turbine engine 16. It should be understood that the nacelle 50 can be configured to be supported relative to the core turbine engine 16 by a plurality of circumferentially spaced outlet guide vanes 52. In addition, a downstream section 54 of the nacelle 50 extends over an outer portion of the core turbine engine 16 so as to define a bypass airflow passage 56 therebetween.

[0037] During operation of the turbofan engine 10, a certain amount of air 58 enters the turbofan engine 10 through the nacelle 50 and / or the associated inlet 60 of the fan section 14. When the certain amount of air 58 passes through the fan blades 40, a first portion of the air 58, as shown by arrow 62, is directed or directed into the bypass airflow passage 56, and a second portion of the air 58, as shown by arrow 64, is directed or directed into the LP compressor 22. The ratio between the first portion of air 62 and the second portion of air 64 is generally referred to as the bypass ratio. The pressure of the second portion of air 64 is then increased when the second portion of air 64 is directed through the high pressure (HP) compressor 24 and enters the combustion section 26, where the second portion of air 64 is mixed with fuel and combusted to provide combustion gases 66.

[0038] The combustion gases 66 are directed through the HP turbine 28 where a portion of the thermal and / or kinetic energy from the combustion gases 66 is extracted via sequential stages of HP turbine stator blades 68 coupled to the casing 18 and HP turbine rotor blades 70 coupled to the HP shaft or spool 34, thereby rotating the HP shaft or spool 34 to support operation of the HP compressor 24. The combustion gases 66 are then directed through the LP turbine 30 where a second portion of the thermal and kinetic energy is extracted from the combustion gases 66 via sequential stages of LP turbine stator blades 72 coupled to the casing 18 and LP turbine rotor blades 74 coupled to the LP shaft or spool 36, thereby rotating the LP shaft or spool 36 to support operation of the LP compressor 22 and / or rotation of the fan 38.

[0039] The combustion gases 66 are then directed through the jet exhaust nozzle section 32 of the core turbine engine 16 to provide propulsion. At the same time, the pressure of the first portion of air 62 is substantially increased as it is directed through the bypass airflow passage 56 before being discharged from the fan nozzle exhaust section 76 of the turbofan engine 10, which also provides propulsion. The HP turbine 28, the LP turbine 30, and the jet exhaust nozzle section 32 at least partially define a hot gas path 78 for directing the combustion gases 66 through the core turbine engine 16.

[0040] Reference now Figure 2 , provides Figure 1 1 is a close-up cross-sectional view of the combustion section 26 of an exemplary turbofan engine 10. More specifically, Figure 2 According to an exemplary embodiment of the present disclosure, a Figure 1 1 is a perspective cross-sectional view of a combustor assembly 100 in a combustion section 26 of an exemplary turbofan engine 10 .

[0041] As shown, the combustor assembly 100 generally includes an inner liner 102 extending between an aft end 104 and a forward end 106 generally along an axial direction A, and an outer liner 108 extending between an aft end 110 and a forward end 112 also generally along the axial direction A. The inner liner 102 and the outer liner 108 together at least partially define a combustion chamber 114 therebetween. The inner liner 102 and the outer liner 108 are attached to annular domes, respectively. More specifically, the combustor assembly 100 includes an inner annular dome 116 attached to the forward end 106 of the inner liner 102 and an outer annular dome 118 attached to the forward end 112 of the outer liner 108. Although the inner annular dome 116 and the outer annular dome 118 are shown to each include a closed surface that defines a slot 122 for receiving the forward ends 106, 112 of the respective inner liner 102 and the outer liner 108, any suitable attachment scheme may be utilized to attach the liner to the respective dome. Furthermore, although the exemplary combustor assembly 100 is shown to include an inner annular dome and an outer annular dome, it should be understood that in other embodiments, the domes may be formed as a single dome configuration or any other suitable multi-dome configuration (eg, 3 domes, etc.).

[0042] The combustor assembly 100 also includes a plurality of fuel-air mixers 124 spaced apart along a circumferential direction within the outer dome 118. More specifically, the plurality of fuel-air mixers 124 are disposed along a radial direction R between the outer dome 118 and the inner dome 116. Compressed air from the compressor section of the turbofan engine 10 flows into or through the fuel-air mixers 124, where the compressed air is mixed with fuel and ignited to produce combustion gases 66 within the combustion chamber 114. The inner dome 116 and the outer dome 118 are configured to facilitate providing such a flow of compressed air from the compressor section into or through the fuel-air mixers 126. For example, the outer dome 118 includes an outer shroud 126 at a forward end 128, and the inner dome 116 similarly includes an inner shroud 130 at a forward end 132. Outer shroud 126 and inner shroud 130 may help direct the flow of compressed air from compressor section 26 into or through one or more fuel-air mixers.

[0043] In addition, both the inner dome 116 and the outer dome 118 include an attachment portion that is configured to facilitate installation of the combustor assembly 100 within the turbofan engine 10. For example, the outer dome 118 includes an attachment extension 134 that is configured to be mounted to an outer combustor casing (not shown), while the inner dome 116 includes a similar attachment extension 138 that is configured to be attached to an annular support member (not shown) within the turbofan engine 10. In certain exemplary embodiments, the inner dome 116 can be integrally formed as a single annular component, and similarly, the outer dome 118 can also be integrally formed as a single annular component. However, it should be understood that in other exemplary embodiments, the inner dome 116 and / or the outer dome 118 can alternatively be formed by one or more components joined in any suitable manner. For example, with reference to the outer dome 118, in certain exemplary embodiments, the outer shroud 126 can be formed separately from the outer dome 118 and attached to the front end 128 of the outer dome 118 using, for example, a welding process. Similarly, the attachment extension 134 may also be formed separately from the outer dome 118 and attached to the front end 128 of the outer dome 118 using, for example, a welding process. Additionally or alternatively, the inner dome 116 may have a similar configuration.

[0044] Still reference Figure 2 The exemplary combustor assembly 100 also includes a plurality of circumferentially arranged heat shields 142 positioned around each fuel-air mixer 124. For the depicted embodiment, the heat shields 142 are attached to and extend between the outer dome 118 and the inner dome 116. The heat shields 142 are configured to protect certain components of the turbofan engine 10 from the relatively extreme temperatures of the combustion chamber 114.

[0045] It should be understood that each of the heat shield 142, the inner liner 102 and the outer liner 104 is exposed to relatively harsh conditions of relatively high temperatures during operation of the gas turbine engine. Thus, a thermal barrier coating 146 is provided at least on the exposed surface of one or more of these components.

[0046] Especially for Figure 2 In an embodiment of the present invention, the heat shield 142 includes a thermal barrier coating 146 for protecting the underlying structure of the heat shield 142. The thermal barrier coating 146 may be a ceramic coating or any other suitable coating.

[0047] Furthermore, it will be appreciated that through operation of the gas turbine engine 10, one or more portions of the thermal barrier coating 146 may wear or degrade faster than other portions of the thermal barrier coating 146. For example, Figure 2 As schematically shown, the thermal barrier coating 146 includes a worn portion 148 between adjacent fuel air mixers 124 . Figure 2The schematically shown worn portion 148 may represent spalling of the thermal barrier coating.

[0048] Reference now Figure 3 , an inspection and repair tool 200 according to an exemplary embodiment of the present disclosure is provided, and the inspection and repair tool 200 can be used with the above reference Figure 1 and 2 An exemplary gas turbine engine 10 and components thereof are described for use together.

[0049] for Figure 3 In an exemplary embodiment of the present invention, the inspection and repair tool 200 generally includes an elongated insertion member 202 and an instrument body 204 attached to the elongated insertion member 202 at a distal end 206 of the elongated insertion member 202. As will be described in more detail below, the instrument body 204 can be configured to perform one or more inspection and / or repair operations.

[0050] More specifically, for Figure 3 In an embodiment of the present invention, the inspection and repair tool 200 utilizes a robotic arm assembly 208 (sometimes also referred to as a "snake arm" assembly), and the elongated insertion member 202 is configured as a robotic arm of the robotic arm assembly 208. The robotic arm assembly 208 generally defines a vertical direction V, a longitudinal direction L, and a transverse direction (perpendicular to the longitudinal direction L and the vertical direction V; not shown). In addition to the elongated insertion member 202 or robotic arm, the robotic arm assembly 208 also includes a base 210. Although not shown, the robotic arm defines a fluid passage therethrough. The fluid passage can be directly in fluid communication with a supply line and / or a fluid heater, or alternatively can be in fluid communication with a fluid source through the base 210.

[0051] For the illustrated embodiment, the base 210 generally includes one or more motors 212 operable with the manipulator to actuate the manipulator. Thus, the depicted manipulator assembly 208 may be referred to as a motorized manipulator assembly. Additionally, for the illustrated embodiment, the manipulator includes a plurality of segments 214 (also referred to as "links") sequentially arranged between a root end 216 and a distal end 206 and extending from the base 210, e.g., for the illustrated embodiment, generally along a longitudinal direction L of the manipulator assembly 208. Notably, for the illustrated embodiment, the manipulator is coupled to the base 210 at its root end 216.

[0052] Furthermore, with particular reference to the robotic arm, as shown, each segment 214 can be moved along at least two degrees of maneuver relative to a leading adjacent segment 214 (i.e., the segment 214 immediately in front of the segment 214 / toward the distal end 206) and a trailing adjacent segment (i.e., the segment 214 immediately behind the segment 214 / toward the root end 216) to form Figure 3208. For example, each segment 214 can be moved upward or downward relative to the front adjacent segment 214 and the rear adjacent segment 214 along the vertical direction V of the robotic arm assembly 208. However, it will be further understood that for the exemplary embodiment depicted, each segment 214 can be further moved relative to the corresponding front adjacent and rear adjacent segments 214 along at least four operating degrees. For example, each segment 214 can also be moved along a lateral direction (perpendicular to the longitudinal direction L and the vertical direction V) relative to the front adjacent and rear adjacent segments 214. In this way, the robotic arm can be generally movable to form various three-dimensional shapes. In this way, the robotic arm can be movable to position the distal end 206 and the appliance body 204 to be adjacent to multiple different components inside the gas turbine engine.

[0053] Briefly, as noted, the depicted robotic arm assembly 208 utilizes a motorized robotic arm assembly. Thus, it will be appreciated that, in at least some exemplary embodiments, the one or more motors 212 of the base 210 can generally pull various wires (not shown) extending through the robotic arm and terminating at the various segments 214 of the robotic arm. By pulling these various wires, the one or more motors 212 of the base 210 can control the movement of the segments 214 of the robotic arm.

[0054] However, in other embodiments, any other suitable configuration may be provided to control the robotic arm.In certain exemplary embodiments, the motor 212 may be operably coupled to a controller of the inspection and repair tool 200 (such as the controller 220 of the inspection and repair tool 200 discussed below).

[0055] However, it will be further understood that in other exemplary embodiments, other elongated insert members 202 may also be provided. For example, in other embodiments, the elongated insert member 202 may be a manual serpentine arm assembly that is manually moved into position. Alternatively, the elongated insert member 202 may be a flexible or semi-flexible tube that may be bent into a desired shape to position its distal end 206 at a desired location inside the gas turbine engine. Alternatively, the elongated insert member 202 may be a series of links having a predetermined shape that are selectively rigidified so that when moved into a rigid position to position the appliance body 204 at a desired location inside the gas turbine engine, they form a desired shape. Other configurations are also contemplated.

[0056] Still refer to Figure 3 The example inspection and repair tool 200 is shown. The example inspection and repair tool 200 also includes a controller 220 . Figure 3The example controller 220 depicted in FIG. 2 is configured to receive data from aspects of the example inspection and repair tool 200 (eg, from the tool body 204 as described below) and, for example, make control decisions for the inspection and repair tool 200 based on the received data.

[0057] With particular reference to the operation of the controller 220, in at least some embodiments, the controller 220 may include one or more computing devices 222. The computing devices 222 may include one or more processors 222A and one or more memory devices 222B. The one or more processors 222A may include any suitable processing device, such as a microprocessor, a microcontroller, an integrated circuit, a logic device, and / or other suitable processing device. The one or more memory devices 222B may include one or more computer-readable media, including but not limited to non-transitory computer-readable media, RAM, ROM, a hard drive, a flash drive, and / or other memory devices.

[0058] One or more memory devices 222B may store information accessible by one or more processors 222A, including computer-readable instructions 222C that may be executed by one or more processors 222A. Instructions 222C may be any set of instructions that, when executed by one or more processors 222A, cause one or more processors 222A to perform operations. In some embodiments, instructions 222C may be executed by one or more processors 222A to cause one or more processors 222A to perform operations, such as any operations and functions for which controller 220 and / or computing device 222 are configured, such as operations (e.g., method 300) for operating inspection and repair tool 200 as described herein and / or any other operations or functions of one or more computing devices 222. Instructions 222C may be software written in any suitable programming language or that may be implemented in hardware. Additionally and / or alternatively, instructions 222C may be executed in logically and / or virtually separate threads on processor 222A. Memory device 222B may further store data 222D that may be accessed by processor 222A.

[0059] The computing device 222 may also include a network interface 222E for communicating, for example, with other components of the inspection and repair tool 200, a gas turbine engine being repaired, an aircraft including a gas turbine engine, and the like. For example, in the embodiments described above, the gas turbine engine and / or the inspection and repair tool 200 include one or more sensors for sensing data indicative of one or more parameters of the inspection and repair tool 200, the gas turbine engine, or both. The controller 220 is operably coupled to the one or more sensors via, for example, the network interface 222E, so that the controller 220 can receive data indicative of various operating parameters sensed by the one or more sensors during operation. The network interface 222E may include any suitable components for interfacing with one or more wired / wireless communication networks, including, for example, transmitters, receivers, ports, controllers, antennas, and / or other suitable components.

[0060] Reference now Figure 4 , provides a close-up side cross-sectional view of a combustor assembly 154 according to an exemplary embodiment of the present disclosure, and a schematic diagram of an inspection and repair tool 200 according to the present disclosure. In certain exemplary embodiments, Figure 4 The inspection and maintenance tool 200 can be used with Figure 3 The inspection and repair tool 200 is constructed in a similar manner, and Figure 4 The burner assembly 154 may be positioned in Figure 2 1. The combustion section 114 of the exemplary turbofan engine 100 of FIG. 1. Thus, it should be appreciated that the exemplary combustor assembly 154 generally defines an axial direction A, a radial direction R, and a circumferential direction C.

[0061] Referring first to the depicted exemplary combustor assembly 154, the combustor assembly 154 generally includes an inner liner 156 extending generally along an axial direction A, and an outer liner 158 also extending generally along the axial direction A. The inner liner 156 and the outer liner 158 together at least partially define a combustion chamber 160 therebetween. The inner liner 156 and the outer liner 158 are both attached to an annular dome. More specifically, the annular dome includes an inner dome segment 162 attached to the inner liner 156 and an outer dome segment 164 attached to the outer liner 158. The inner dome segment 162 and the outer dome segment 164 may be integrally formed (or alternatively may be formed from multiple components attached in any suitable manner), and may each extend along a circumferential direction C to define an annular shape. The combustor assembly 154 also includes a fuel nozzle 166 at least partially positioned within the annular dome and a heat shield 168 positioned around the fuel nozzle 166. One or more of the inner and outer dome segments 162 , 164 and the heat shield 168 may include a thermal barrier coating thereon.

[0062] During operation of a gas turbine engine including the illustrated exemplary combustor assembly 154, the temperatures within the combustion chamber 160 may be relatively high, and the thermal barrier coating on one or more of the inner and outer dome segments 162, 164 and the heat shield 168 may degrade over time. Accordingly, the present disclosure generally provides an inspection and repair tool 200 to inspect one or more of these components for such degradation and repair the degradation in situ (i.e., when the combustor assembly 154 is installed in the gas turbine engine), and also without significantly disassembling the gas turbine engine (e.g., removing components to expose degraded thermal barrier coating components of the gas turbine engine).

[0063] Referring now specifically to the exemplary inspection and repair tool 200, it will be appreciated that the burner assembly 154 is surrounded by a shell 224. For the illustrated embodiment, the shell 224 and the outer liner 158 of the burner assembly 154 together define an access port 226. The access port 226 may be, for example, an igniter port of a currently existing or future added burner assembly 154 or any other suitable access port 226 (e.g., a borescope port, etc.). As described above, the inspection and repair tool 200 generally includes an elongated insert member 202 and an implement body 204 attached to the elongated insert member 202. Figure 3 As in the exemplary embodiment, Figure 4 The elongated insertion member 202 of the inspection and repair tool 200 is configured as a robotic arm. The robotic arm is configured to guide the tool body 204 through the access port 226 and into the interior of the gas turbine engine, and more specifically, the interior of the combustor assembly 154, or more specifically, the combustion chamber 160 of the exemplary combustor assembly 154 depicted.

[0064] In this manner, it will be appreciated that the inspection and maintenance tool 200 may be used to perform one or more inspection and maintenance operations within the interior of a gas turbine engine, and more specifically, within a combustor assembly, by directing the instrument body 204 within the interior. The instrument body 204 may include one or more instruments to facilitate inspection of the interior. For example, as will be described in greater detail below, the instrument body 204 may include a vision system for providing feedback to assist in directing the instrument body 204 within the interior and inspecting one or more components within the interior. For example, the vision system may be used to inspect thermal barrier coatings on the inner dome 162, the outer dome 164, the heat shield 168, and the like. Additionally, the instrument body 204 may include one or more instruments to facilitate maintenance of the interior. For example, the instrument body 204 may include a device for spraying a thermal barrier coating replenisher onto a degraded portion of the thermal barrier coating within the interior (e.g., spraying onto the above referenced portion). Figure 2 The nozzle of the thermal barrier coating 146 discussed above is on the worn portion 148 .

[0065] Reference now Figure 5 , provides a close-up perspective view of the distal end 206 of the inspection and repair tool 200 according to an exemplary embodiment of the present disclosure. The exemplary inspection and repair tool 200 can be used in the same manner as the above reference Figure 3 and Figure 4 The exemplary inspection and repair tool 200 depicted is constructed in substantially the same manner. For example, the inspection and repair tool 200 generally includes an elongated insertion member 202 and an implement body 204 attached to the elongated insertion member 202 at a distal end 206 of the elongated insertion member 202 .

[0066] For the illustrated embodiment, the appliance body 204 includes an appliance for performing inspection and maintenance operations. Specifically, for the illustrated embodiment, the appliance body 204 includes a base 230 extending along the longitudinal direction L2 and a vision system. More specifically, for the illustrated embodiment, the vision system is at least partially positioned within the base 230 or coupled to the base 230. More specifically, for the illustrated embodiment, the vision system includes a plurality of cameras 232, and in particular includes a first camera 232A and a second camera 232B. The first camera 232A and the second camera 232B are spaced apart along the longitudinal direction L2 of the base 230.

[0067] like Figure 5 As shown, the first camera 232A defines a first field of view 234A, and the second camera 232B defines a second field of view 234B. The first field of view 234A overlaps with the second field of view 234B. More specifically, for the illustrated embodiment, the first field of view 234A overlaps with the second field of view 234B at a position 236 within about 12 inches from the base 230 of the fixture body 204 (e.g., within about 8 inches from the base 230 of the fixture body 204, such as within about 6 inches, such as within about 3 inches, such as within about 1 inch).

[0068] In this manner, the vision system can provide improved feedback for navigating inspection and repair tool 200 within a gas turbine engine and for inspection of the interior of a gas turbine engine. For example, when operating inspection and repair tool 200, overlapping fields of view 234A, 234B can provide desired depth perception.

[0069] Additionally, it will be appreciated that in certain exemplary embodiments, the tool body 204 may additionally or alternatively include any other suitable means for determining the distance between the tool body 204 and the inspected component. For example, the tool body 204 may include one or more laser depth sensors, or other suitable hardware (not shown).

[0070] Furthermore, it will be appreciated that the one or more cameras 232 of the vision system may be operably coupled to the controller 220 (see Figure 3-4), so that the vision system and controller 220 can be used to inspect the interior of the gas turbine engine. For example, the vision system can be configured to communicate an image of the thermal barrier coating of the interior to the controller 220 along with location information indicating where the thermal barrier coating is inside. The controller 220 can then be configured to compare the image to one or more baseline images to determine whether the thermal barrier coating is damaged. For example, briefly referring to Figure 6 , at the dome of the burner assembly 154 (similar to Figure 3 164). The thermal barrier coating 146 includes a damaged portion 148, referred to as a spalling, where the thermal barrier coating 146 has worn away. The controller 220 may receive the image, compare it to one or more baseline images, and use, for example, pixel-by-pixel analysis, and determine that there is damage on the thermal barrier coating 146 that requires repair. As discussed below, the extent (e.g., depth, width, area, shape, etc.) of the damaged portion 148 may be determined by the analysis of the controller 220 to facilitate customized repair of such damaged portion 148.

[0071] However, it will be appreciated that in other exemplary embodiments, the controller 220 may utilize any other suitable analysis techniques to determine whether any damage to the thermal barrier coating 146 exists, the extent of such damage, etc. For example, in other exemplary embodiments, the controller 220 may utilize a machine learning tool that is trained to identify the presence and / or extent of damage to the thermal barrier coating 146 or other components within the engine.

[0072] Still refer to Figure 5 , and now also refer to Figure 7 , provides Figure 5 FIG. 2 is another schematic diagram of an exemplary inspection and repair tool 200. It will be further appreciated that the tool body 204 includes a spray head 240. The spray head 240 is movably coupled to the base 230 of the tool body 204 and can be moved in a manner such as Figure 7 The retracted position shown and Figure 5 between the extended positions shown.

[0073] Specifically, for the illustrated embodiment, the spray head 240 is rotatably coupled to the base 230 about a pin connection 242. For the illustrated embodiment, the spray head 240 is rotatably coupled to the base 230 about a pin connection 242. Figure 7 The retracted position shown is similar to Figure 5 The rotation between the extended positions shown is at least about 30 degrees (e.g., at least about 45 degrees, such as at least about 90 degrees) and less than 360 degrees. It is worth noting that for the illustrated embodiment, the spray head 240 is rotated along Figure 5The reference arrow 244 in FIG. 2 is rotated in a plane parallel to the longitudinal direction L2. In this manner, when in the extended position, the spray head 240 defines a first angle (e.g., about 90 degrees for the illustrated embodiment) with the longitudinal direction L2, and when in the retracted position, the spray head 240 defines a second angle (e.g., about 0 degrees for the illustrated embodiment) different from the first angle with the longitudinal direction L2.

[0074] In this manner, when the nozzle 240 is in the retracted position, the tool body 204 defines a smaller cross-sectional profile to facilitate insertion of the tool body 204 into the interior of the gas turbine engine (eg, through an access port, such as Figure 4 Subsequently, once the appliance body 204 is inside, the spray head 240 can be moved from the retracted position to the extended position to allow operation of the spray head 240, as described below. The spray head 240 can be spring loaded.

[0075] It is noted that for the illustrated embodiment, the spray head 240 is fluidly connected to the fluid source via one or more fluid channels 246 extending along the length of the elongated insert member 202. Figure 5 and Figure 7 The one or more fluid channels 246 shown in dashed lines in the figure may be separate fluid conduits extending through the elongated insert member 202, or may be integrally formed within the elongated insert member 202. The one or more fluid channels 246 may provide a repair material flow 248 to the spray head 240 to be sprayed on the damaged portion of the thermal barrier coating to repair the damaged portion of the thermal barrier coating. The repair material 248 may be a slurry formed of a powder and a carrier, which may be formed as a replenisher for the thermal barrier coating. For example, the powder may be a machine-curable ceramic powder mixture configured to bond to the damaged portion of the thermal barrier coating.

[0076] Despite Figure 5 and 7 246, but in other exemplary embodiments, the inspection and repair tool 200 may include multiple channels. For example, the inspection and repair tool 200 may include a channel for repair material 248, a channel for cleaning and conditioning fluids, a channel for curing fluids, etc. Each of these channels may be fixedly or selectively in fluid communication with the spray head 240.

[0077] Still reference Figure 5It will be further understood that the spray head 240 defines an outlet 250 for spraying the repair material 248 onto the damaged portion of the thermal barrier coating. For the illustrated embodiment, the outlet 250 is within the field of view 234 of the vision system. More specifically, for the illustrated embodiment, the outlet 250 is within the first field of view 234A and / or the second field of view 234B of the first and second cameras 232 of the vision system. In this manner, the controller 220 is able to confirm the position of the spray head 240 and the coverage of the sprayed repair material 248 (or other material / fluid).

[0078] In addition, it should still be understood that the exemplary device body 204 is capable of moving to assist in the spraying operation. More specifically, for the illustrated embodiment, the device body 204 includes a fixed portion 252 and a rotating portion 254. The rotating portion 254 includes a base 230 and a spray head 240, and the rotating portion 254 is rotatably coupled to the fixed portion 252 so that the rotating portion 254 can rotate in a circumferential direction C around the longitudinal direction L2. The fixed portion 252 includes one or more motors positioned therein for selectively moving the rotating portion 254 around the circumferential direction C. Therefore, it will be appreciated that in certain exemplary embodiments, the device body 204 can move the spray head 240 along the circumferential direction C during the spraying operation to provide a more uniform coverage of the sprayed repair material 248 (or other material / fluid).

[0079] It should be understood that the above-described exemplary inspection and repair tool 200 is provided as an example only. In other exemplary embodiments, the inspection and repair tool 200 may have any other suitable configuration. For example, in other exemplary embodiments, the spray head 240 may be movably coupled to the base 230 in any other suitable manner (e.g., rotation and sliding, etc.), the spray head 240 may have any other configuration of the outlet 250 (e.g., a linear array or other pattern of the outlet 250), the appliance body 204 may have any other suitable vision system or inspection system, the appliance body 204 may be configured to rotate in any other suitable manner, etc.

[0080] Reference now Figure 8 , a method 300 for inspecting and repairing the surface of a component of a gas turbine engine is provided. The method 300 may be performed according to the above Figures 1 to 7 One or more of the exemplary configurations discussed may be utilized with an inspection and repair tool.

[0081] The method 300 includes inserting an inspection and service tool into an interior of a gas turbine engine at (302). In certain exemplary aspects, inserting the inspection and service tool into an interior of the gas turbine engine at (302) may include inserting the inspection and service tool into the interior of the gas turbine engine through an inspection port of the engine to position an instrument body of the inspection and service tool within a combustion chamber of a combustor assembly of the engine.

[0082] The method 300 further includes inspecting the surface of the component using the inspection and repair tool at (304). For the illustrated embodiment, inspecting the surface of the component using the inspection and repair tool at (304) includes inspecting the surface of the component using a plurality of cameras of the inspection and repair tool at (306). In certain exemplary aspects, the plurality of cameras includes two cameras defining overlapping fields of view. Further for the illustrated embodiment, inspecting the surface of the component using the inspection and repair tool at (304) includes measuring a distance between the surface of the component and the inspection and repair tool at (308).

[0083] It is worth noting that for Figure 8 In an exemplary aspect of the present invention, the inspection and repair tool includes a spray head that pivots between a retracted position and an extended position. For such exemplary aspects, inspecting the surface of the component using the inspection and repair tool at (304) includes, after inserting the inspection and repair tool into the interior of the gas turbine engine at (307), moving the spray head from the retracted position to the extended position.

[0084] Additionally, in certain exemplary aspects, inspecting the surface of the component using the inspection and repair tool at (304) includes moving the inspection and repair tool within the cavity using a serpentine arm assembly at (309).

[0085] The method 300 further includes determining, at (310), that the surface of the component includes a defect based on inspection of the surface of the component using the inspection and repair tool. In this manner, it will also be understood that inspecting the surface of the component using the inspection and repair tool at (304) may include utilizing any suitable inspection and analysis techniques. For example, in certain exemplary aspects, inspecting the surface of the component using the inspection and repair tool at (304) includes superimposing the exemplary image relative to one or more captured images at (312), and determining, at (310), that the surface of the component includes a defect includes determining, at (311), that the surface of the component includes a defect based on a comparison of the superimposed exemplary image relative to the one or more captured images.

[0086] Furthermore, it will be appreciated that in certain exemplary aspects, the surface of the component is a thermal barrier coating of the component, and determining at (310) that the surface of the component includes a defect includes receiving data indicating spalling of the thermal barrier coating at (314). The data indicating spalling of the thermal barrier coating may be the comparative data described above, or may be the result of a machine learning tool trained to identify spalling.

[0087] The method 300 further includes performing repair of the surface of the component from within the gas turbine engine using the inspection and repair tool at (316), the inspection and repair tool remaining within the gas turbine engine between inspecting the component and performing repair of the surface of the component. In this manner, it will be appreciated that both inspecting the surface of the component at (304) and performing repair of the surface of the component at (316) can be accomplished in situ without having to remove the inspection and repair tool. This can allow for a more time-efficient and cost-effective inspection and repair process.

[0088] Still refer to Figure 8 It will be appreciated that in certain exemplary aspects, repairing the surface of the component at (316) also includes spraying a thermal barrier coating repair agent on the spalling of the thermal barrier coating at (318).

[0089] Additionally, in certain exemplary aspects, such as the exemplary aspect shown, performing repair on the surface of the component at (316) also includes positioning a spray head of the inspection and repair tool at (320) based at least in part on a vision system of the inspection and repair tool to spray material onto the component.

[0090] Furthermore, in certain exemplary aspects, such as the depicted exemplary aspect, performing repair of the surface of the component at (316) additionally includes spraying a pretreatment material on the surface of the component at (322), and subsequently spraying a repair material on the surface of the component. With such exemplary aspects, the inspection and repair tool can remain within the interior of the gas turbine engine between spraying the pretreatment material on the surface of the component and spraying the repair material on the surface of the component.

[0091] This written description uses examples to disclose the invention, including the best mode, and also enables any person skilled in the art to practice the invention, including making and using any device or system and performing any combined methods. The patentable scope of the invention is defined by the claims, and may include other examples that occur to those skilled in the art. If such other examples include structural elements that do not differ from the literal language of the claims, or if they include equivalent structural elements that do not differ substantially from the literal language of the claims, then these other examples are intended to fall within the scope of the claims.

[0092] Further aspects of the invention are provided by the subject matter of the following clauses:

[0093] A method for inspecting and repairing the surface of a component of a gas turbine engine, comprising: inserting an inspection and repair tool into the interior of the gas turbine engine; inspecting the surface of the component using the inspection and repair tool; and repairing the surface of the component from the interior of the gas turbine engine using the inspection and repair tool, wherein the inspection and repair tool remains in the interior of the gas turbine engine between inspecting the component and repairing the surface of the component.

[0094] The method of one or more of these clauses further comprises determining that the surface of the component includes a defect based on the inspection of the surface of the component using the inspection and repair tool.

[0095] The method of one or more of these clauses, wherein inspecting the surface of the component using the inspection and repair tool includes inspecting the surface of the component using a plurality of cameras of the inspection and repair tool.

[0096] The method of one or more of these clauses, wherein the plurality of cameras includes two cameras defining overlapping fields of view.

[0097] The method of one or more of these clauses, wherein inspecting the surface of the component with the inspection and repair tool further comprises measuring a distance between the surface of the component and the inspection and repair tool.

[0098] The method of one or more of these clauses, wherein inspecting the surface of the component using the inspection and repair tool includes superimposing an exemplary image relative to one or more captured images.

[0099] The method according to one or more of these clauses, wherein the surface of the component is a thermal barrier coating of the component.

[0100] The method according to one or more of these clauses further includes: determining that the surface of the component includes a defect based on the inspection of the surface of the component using the inspection and repair tool, and wherein determining that the surface of the component includes a defect includes receiving data indicating spalling of the thermal barrier coating.

[0101] The method according to one or more of these clauses, wherein performing the repair of the surface of the component includes spraying a thermal barrier coating replenisher at the spalling of the thermal barrier coating.

[0102] The method of one or more of these clauses, wherein performing the repair of the surface of the component includes positioning a spray head of the inspection and repair tool based at least in part on a vision system of the inspection and repair tool to spray material onto the component.

[0103] A method according to one or more of these clauses, wherein performing the repair of the surface of the component includes spraying a pretreatment material on the surface of the component and subsequently spraying a repair material on the surface of the component, and wherein the inspection and repair tool remains in the interior of the gas turbine engine between spraying the pretreatment material on the surface of the component and spraying the repair material on the surface of the component.

[0104] The method of one or more of these clauses, wherein the inspection and repair tool includes a camera and a spray head defining a field of view, wherein the spray head includes an outlet, and wherein the outlet is within the field of view.

[0105] The method of one or more of these clauses, wherein the camera is a first camera, wherein the field of view is a first field of view, wherein the inspection and repair tool additionally includes a second camera defining a second field of view, wherein the first field of view and the second field of view together define an overlapping field of view, wherein the exit is within the overlapping field of view

[0106] The method according to one or more of these clauses, wherein the inspection and repair tool includes a spray head, and wherein the spray head pivots between a retracted position and an extended position.

[0107] The method of one or more of these clauses, wherein inspecting the surface of the component with the inspection and repair tool comprises moving the inspection and repair tool within an interior of a cavity using a snake-arm robot.

[0108] A tool for inspecting, repairing, or inspecting and repairing components within a gas turbine engine, comprising: an elongated insertion member; and an instrument body, the instrument body being attached to the elongated insertion member, the elongated insertion member being configured to guide the instrument body within the interior of the gas turbine engine, the instrument body comprising a base and a spray head, the spray head being movably connected to the base and being movable between a retracted position and an extended position.

[0109] The tool according to one or more of these clauses, wherein when the spray head is in the retracted position, the implement body defines a smaller cross-sectional profile to facilitate insertion of the implement body into the interior of the gas turbine engine.

[0110] The tool according to one or more of these clauses, wherein the tool body further includes a vision system, the vision system at least partially positioned within or coupled to the base.

[0111] The tool of one or more of these clauses, wherein the vision system defines a field of view, wherein the spray head includes an outlet, and wherein the outlet is within the field of view.

[0112] The tool according to one or more of these clauses, wherein the elongated insertion member is a robotic tool including one or more fluid channels extending along its length.

Claims

1. A tool for inspecting, repairing or inspecting and repairing a component in a gas turbine engine, characterized in that include: an elongated insertion member; as well as an implement body attached to the elongated insert member, the elongated insert member being configured to guide the implement body within the interior of the gas turbine engine, the implement body including a base and a spray head movably coupled to the base and movable relative to the base between a retracted position and an extended position; wherein the apparatus body further comprises a plurality of cameras, the plurality of cameras comprising two cameras defining overlapping fields of view; wherein the device body comprises a fixed part and a rotating part, the rotating part comprises the base and the spray head and is rotatably connected to the fixed part; and Wherein the stationary portion comprises one or more motors positioned to selectively rotate the rotating portion.

2. The tool according to claim 1, characterized in that in, When the nozzle is in the retracted position, the tool body defines a smaller cross-sectional profile to facilitate insertion of the tool body into the interior of the gas turbine engine.

3. The tool according to claim 1, characterized in that in, The plurality of cameras are at least partially positioned within or coupled to the base.

4. The tool according to claim 3, characterized in that in, The showerhead includes an outlet, and wherein the outlet is within the field of view.

5. The tool according to claim 1, characterized in that in, The elongated insertion member is a robotic tool that includes one or more fluid channels extending along its length.

6. The tool according to claim 1, characterized in that in, The two cameras are spaced apart along the longitudinal direction of the device body.

7. A method for inspecting and repairing the surface of a component of a gas turbine engine, characterized in that include: inserting an instrument body of an inspection and repair tool into the interior of the gas turbine engine via an elongated insertion member, wherein the instrument body includes a fixed portion and a rotating portion, the rotating portion including a base and a spray head and rotatably coupled to the fixed portion; selectively rotating the rotating portion using one or more motors of the fixed portion of the appliance body; inspecting the surface of the component using a plurality of cameras of the inspection and repair tool, wherein the plurality of cameras includes two cameras defining overlapping fields of view; Repair of the surface of the component is performed from the interior of the gas turbine engine using the inspection and repair tool, the inspection and repair tool remaining within the interior of the gas turbine engine between inspecting the component and performing the repair of the surface of the component.

8. The method according to claim 7, characterized in that Further including: The surface of the component is determined to include a defect based on the inspection of the surface of the component using the inspection and repair tool.

9. The method according to claim 7, characterized in that: in, Inspecting the surface of the component using the inspection and repair tool further includes measuring a distance between the surface of the component and the inspection and repair tool.

10. The method according to claim 7, characterized in that in, Inspecting the surface of the component using the inspection and repair tool includes superimposing an exemplary image relative to one or more captured images.

11. The method according to claim 7, characterized in that in, The surface of the component is a thermal barrier coating of the component.

12. The method according to claim 11, characterized in that Further including: The surface of the component is determined to include a defect based on the inspection of the surface of the component using the inspection and repair tool, and wherein determining that the surface of the component includes the defect includes receiving data indicative of spalling of the thermal barrier coating.

13. The method according to claim 12, characterized in that in, Performing the repair of the surface of the component includes spraying a thermal barrier coating replenisher on the peeling of the thermal barrier coating.

14. The method according to claim 7, characterized in that in, Performing the repair of the surface of the component includes positioning a spray head of the inspection and repair tool based at least in part on a vision system of the inspection and repair tool to spray material onto the component.

15. The method according to claim 7, characterized in that in, Performing the repair of the surface of the component includes spraying a pretreatment material on the surface of the component and subsequently spraying a repair material on the surface of the component, and wherein the inspection and repair tool remains in the interior of the gas turbine engine between spraying the pretreatment material on the surface of the component and spraying the repair material on the surface of the component.

16. The method according to claim 7, characterized in that in, The inspection and repair tool includes a camera defining a field of view and a spray head, wherein the spray head includes an outlet, and wherein the outlet is within the field of view.

17. The method according to claim 16, characterized in that in, The camera is a first camera, wherein the field of view is a first field of view, wherein the inspection and repair tool additionally includes a second camera defining a second field of view, wherein the first field of view and the second field of view together define an overlapping field of view, wherein the exit is within the overlapping field of view.

18. The method according to claim 7, characterized in that in, The inspection and repair tool includes a spray head, and wherein the spray head pivots between a retracted position and an extended position.

19. The method according to claim 7, characterized in that in, Inspecting the surface of the component using the inspection and repair tool includes moving the inspection and repair tool within a cavity using a snake-arm robot.

Images