Repair device, repair system and repair method for a damaged blade

Abstract

The present disclosure relates to the field of turbine blade repair, in particular, to a damaged blade repair device, a repair system and a repair method. The damaged blade repair device comprises a first gasket, a second gasket, a first clamp and a second clamp, the first gasket has a first clamping surface, the first clamping surface is adapted to the blade basin side profile of the damaged surface of the damaged blade; the second gasket has a second clamping surface, the second clamping surface is adapted to the blade back side profile of the damaged surface. Wherein, the first clamping surface and the second clamping surface are opposite in the first direction, the first clamp and the second clamp are sequentially arranged in the first direction, and the first clamp and the second clamp are connected. Wherein, the first gasket is detachably connected to one side of the first clamp close to the second clamp; the second gasket is detachably connected to one side of the second clamp close to the first clamp. Through the repair device, the repair system and the repair method of the exemplary embodiments of the present disclosure, the damaged turbine blade can be repaired to restore its working performance.

Description

Technical Field

[0001] This disclosure relates to the field of turbine blade repair, and more specifically, to a device, system, and method for repairing damaged blades. Background Technology

[0002] Aero engines are often referred to as the "heart" of an aircraft, and their reliability is crucial for the safe and normal operation of the aircraft. Blades are a key component of aero engines, relying on them to compress and expand gases to generate powerful thrust and propel the aircraft forward. During normal engine operation, extreme environments such as high temperature, high pressure, corrosion, thermal fatigue, and vibration, as well as collisions with foreign objects and friction between the blades and the casing, can cause defects such as chipping or cracking in the blades. Simultaneously, the blades will also suffer damage from corrosion and thermal fatigue. These defects and damage alter the blade's support structure and vibration characteristics, leading to anything from minor component damage and blade failure to severe rotor blade breakage, endangering the safety of the engine and aircraft, and potentially causing significant economic losses and casualties.

[0003] Therefore, there is a need to provide a device, system, and method for repairing damaged turbine blades to restore their working performance.

[0004] It should be noted that the information disclosed in the background section above is only used to enhance the understanding of the background of this disclosure, and therefore may include information that does not constitute prior art known to those skilled in the art. Summary of the Invention

[0005] The purpose of this disclosure is to provide a device and method for repairing damaged turbine blades, so as to repair damaged turbine blades and restore their working performance.

[0006] According to a first aspect of this disclosure, a repair apparatus for damaged blades is provided, comprising: The first gasket has a first clamping surface, which is adapted to the leaf shape of the leaf basin side of the defective leaf. The second pad has a second clamping surface, which is adapted to the leaf shape on the back side of the damaged surface; The first clamp, the first washer is detachably connected to the side of the first clamp near the second clamp; The second clamp, the second washer, is detachably connected to the side of the second clamp near the first clamp; The first clamp and the second clamp are arranged sequentially in the first direction, and the first clamp and the second clamp are connected, with the first clamping surface and the second clamping surface facing each other in the first direction.

[0007] In one exemplary embodiment of this disclosure, The first gasket also has a first outer peripheral surface surrounding the first clamping surface, and the first outer peripheral surface is formed by a plurality of first side surfaces; The second gasket also has a second outer peripheral surface surrounding the second clamping surface, and the second outer peripheral surface is formed by a plurality of second side surfaces; Wherein, at least one first side and at least one second side are coplanar.

[0008] In one exemplary embodiment of this disclosure, The first clamp has a first top surface, which is parallel to a first direction. A portion of the first pad protrudes from the first top surface. Among the plurality of first side surfaces, there is a first repair surface. The angle between the first repair surface and the first top surface is greater than or equal to 0° and less than 90°. The second clamp has a second top surface that is parallel to the first direction, a portion of the second pad protrudes from the second top surface, and one of the plurality of second side surfaces includes a second repair surface. The angle between the second repair surface and the second top surface is greater than or equal to 0° and less than 90°. The first repair surface and the second repair surface are coplanar.

[0009] In one exemplary embodiment of this disclosure, The width of the first gasket in the first direction is not less than 2mm; The width of the second gasket in the first direction shall not be less than 2 mm.

[0010] In one exemplary embodiment of this disclosure, the device further includes a base, one end of which near the first clamp and the second clamp is provided with a mounting groove adapted to the tenon shape of the missing leaf.

[0011] In one exemplary embodiment of this disclosure, The first and second gaskets are made of the same material as the damaged blade.

[0012] According to a second aspect of this disclosure, a repair system for damaged blades is provided, comprising: A device for repairing damaged blades of any of the above-mentioned types; A heating mechanism is installed adjacent to the repair device for the damaged blades; A cladding mechanism, at least a portion of which is located between the first gasket and the second gasket.

[0013] According to a third aspect of this disclosure, a method for repairing a damaged blade is provided, used to repair a damaged blade using the aforementioned damaged blade repair system. The method for repairing a damaged blade includes: Grind the damaged area of ​​the damaged blade to create a damaged surface; The first pad is generated based on the leaf shape on the leaf basin side of the defective surface, and the second pad is generated based on the leaf shape on the leaf back side of the defective surface. The first clamp is made according to the leaf shape on the leaf basin side of the damaged leaf, and the second clamp is made according to the leaf shape on the leaf back side of the damaged leaf. The damaged blade is clamped between the first shim and the second shim, with the first clamping surface and the second clamping surface in close contact with the damaged blade; Connect the first washer to the first clamp, and connect the second washer to the second clamp; Connect the first clamp and the second clamp to fix the first washer and the second washer; Laser cladding was used to repair the damaged blades; Remove the first and second clamps; The damaged blade is machined and polished to make its shape consistent with that of the undamaged blade.

[0014] In one exemplary embodiment of this disclosure, the damaged blade is clamped between a first pad and a second pad, with the first clamping surface and the second clamping surface in close contact with the damaged blade, and the method further includes: A first notch that matches the first outer peripheral surface is machined on the first fixture; A second notch that matches the second outer peripheral surface is machined on the second fixture; The first clamping surface is tightly attached to the leaf basin side of the damaged surface, the first repair surface is aligned with the damaged surface, and at least two first side surfaces are in contact with the first notch. The second clamping surface is pressed tightly against the leaf back side of the defective surface, the second repair surface is aligned with the defective surface, and at least two second side surfaces are in contact with the second notch.

[0015] In one exemplary embodiment of this disclosure, laser cladding repair of damaged blades includes: Heating the damaged blades; Add powder material identical to the material of the damaged blade to the damaged surface, and scan the damaged surface with a laser to melt the damaged blade portion, the first gasket portion, the second gasket portion, and the powder material simultaneously; Cooling the damaged blade, first gasket, and second gasket.

[0016] By implementing the damaged blade repair device, system, and method disclosed herein, damaged thin-walled blades can be repaired, restoring their working performance. During laser cladding, the first and second shims can also participate in the laser cladding, thickening the thin-walled defect area of ​​the blade to match the laser cladding spot range. This allows sub-millimeter-level thin-walled blades to be repaired using laser cladding technology, improving the repair effect without the need for a spot cutting device or automatic spot adjustment system, thus saving costs. Furthermore, the first and second clamps can fix the blade body near the repair end, facilitating stable clamping of the blade during the repair process. After the damaged blade is repaired, the first and second clamps can be removed and reused for repairing other similar damaged blades. Attached Figure Description

[0017] The accompanying drawings, which are incorporated in and form part of this specification, illustrate embodiments consistent with this disclosure and, together with the description, serve to explain the principles of this disclosure. It is obvious that the drawings described below are merely some embodiments of this disclosure, and those skilled in the art can obtain other drawings based on these drawings without any inventive effort.

[0018] To better understand this disclosure, reference may be made to the embodiments shown in the following figures. Components in the figures are not necessarily to scale, and related elements may be omitted to emphasize and clearly illustrate the technical features of this disclosure. Additionally, related elements or components may have different arrangements as known in the art. Furthermore, in the figures, the same reference numerals denote the same or similar components in various figures. Wherein: Figure 1 The illustration shows a schematic diagram of a damaged blade before grinding the damaged area according to an exemplary embodiment of the present disclosure. Figure 2 The illustration shows a schematic diagram of grinding a damaged area to form a defect surface according to an exemplary embodiment of the present disclosure; Figure 3 The illustration shows a schematic diagram of a damaged blade after repair according to an exemplary embodiment of the present disclosure; Figure 4 The schematic diagram illustrates a repair apparatus for a damaged blade according to an exemplary embodiment of the present disclosure; Figure 5 The illustration shows a cross-sectional schematic diagram of a repair device for a damaged blade according to an exemplary embodiment of the present disclosure; Figure 6The schematic diagram illustrates a repair system for a damaged blade according to an exemplary embodiment of the present disclosure; Figure 7 The flowchart illustrates a method for repairing a damaged blade according to an exemplary embodiment of the present disclosure.

[0019] The annotations in the attached figures are explained as follows: 1. Damaged blade; 101. Tenon; 10. First gasket; 11. First repair surface; 20. Second gasket; 21. Second repair surface; 30. Base; 31. Mounting groove; 40. First clamp; 50. Second clamp; 60. Threaded connector; 2. Heating mechanism; 3. Cladding mechanism; 301. Laser scanning device; 302. Powder feeding device. Detailed Implementation

[0020] The technical solutions in the exemplary embodiments of this disclosure will be clearly and completely described below with reference to the accompanying drawings. The exemplary embodiments described herein are for illustrative purposes only and are not intended to limit the scope of protection of this disclosure. Therefore, it should be understood that various modifications and changes can be made to the exemplary embodiments without departing from the scope of protection of this disclosure.

[0021] Unless otherwise specified or stated, the terms "connection," "fixed," etc., should be interpreted broadly. For example, "connection" can be a fixed connection, a detachable connection, or an integral connection; it can be a direct connection or an indirect connection through an intermediate medium. Those skilled in the art can understand the specific meaning of the above terms in this disclosure according to the specific circumstances.

[0022] Furthermore, it should be understood that the directional terms such as "upper" and "lower" described in the exemplary embodiments of this disclosure are for convenience only, for example, based on the angles shown in the accompanying drawings, and should not be construed as limiting the exemplary embodiments of this disclosure.

[0023] The inventors discovered that a repair method combining laser cladding and adaptive grinding can achieve good precision and performance in repaired blades. The principle of laser cladding technology is to use a high-energy laser beam to melt alloy powder pre-prepared on the substrate surface or delivered to the substrate surface via a powder feeding device, forming a molten pool, which then rapidly solidifies to form a cladding layer. Therefore, the resulting cladding layer has advantages such as low dilution rate, small heat-affected zone, and metallurgical bonding with the substrate, making it an important technology for the repair of aero-engine turbine blades.

[0024] However, in related technologies, when using laser cladding technology to repair damaged blades, the laser spot size is typically 1-5mm, while the wall thickness of most thin-walled blades is less than 0.5mm, far smaller than the laser spot size. This results in suboptimal repair results and a heavy workload for subsequent grinding and repair processes. Furthermore, if a laser spot cutting device is used to remove areas with lower energy at the edge of the laser spot, the uneven variation in blade wall thickness causes changes in laser power. Using an automatic spot adjustment system to address this issue would significantly increase the complexity of the process, and the temperature control of the cladding layer would be less than ideal.

[0025] To address the aforementioned problems, this disclosure provides a device, system, and method for repairing damaged turbine blades, thereby restoring their operational performance.

[0026] According to the first aspect of this disclosure, a device for repairing damaged blades is provided, with reference to the attached drawing. Figures 1 to 5 The device includes a first gasket 10, a second gasket 20, a first clamp 40, and a second clamp 50. The first gasket 10 has a first clamping surface that conforms to the leaf shape on the leaf base side of the damaged leaf 1. The second gasket 20 has a second clamping surface that conforms to the leaf shape on the leaf back side of the damaged surface. The first and second clamping surfaces are opposite each other in a first direction. The first clamp 40 and the second clamp 50 are sequentially arranged in the first direction and connected to each other. The first gasket 10 is detachably connected to the side of the first clamp 40 closest to the second clamp 50; the second gasket 20 is detachably connected to the side of the second clamp 50 closest to the first clamp 40.

[0027] First refer to Figure 1 and Figure 2 As shown, for aero-engine turbine blades, the two sides of the turbine blade are the blade basin side and the blade back side, respectively. The blade basin side is the concave surface of the blade body, and the blade back side is the convex surface of the blade body. The blade tip is prone to impact during operation, and the blade tip wall is relatively thin. Therefore, the damaged area of ​​the defective blade 1 is mostly located at the blade tip. After some material of the defective blade 1 peels off, it usually forms an irregularly shaped damaged area. Before repair, the damaged area needs to be ground to remove the irregular parts and the area affecting the repair radius. Unless otherwise specified, the term "damaged surface" in this disclosure refers to the surface formed after grinding the damaged area.

[0028] The first clamping surface described in the exemplary embodiments of this disclosure, which is adapted to the leaf shape on the leaf base side, refers to the first clamping surface being a convex surface that can closely fit the concave surface of the leaf base side. Correspondingly, the second clamping surface is adapted to the leaf shape on the leaf back side, that is, the second clamping surface is a concave surface that can closely fit the convex surface of the leaf back side. The first clamp 40 and the second clamp 50 are sequentially arranged in a first direction. After the first gasket 10 and the second gasket 20 are connected to the first clamp 40 and the second clamp 50, the first clamping surface and the second clamping surface are opposite to each other in the first direction.

[0029] When performing laser cladding repair on the damaged blade 1 using the damaged blade repair apparatus of the exemplary embodiments of this disclosure, refer to Figure 4 and Figure 5 As shown, the first clamping surface and the second clamping surface are opposite each other in the first direction. The first clamping surface and the second clamping surface can respectively fit tightly against both sides of the damaged part of the blade, thereby clamping the blade and facilitating subsequent laser cladding repair. Moreover, during laser cladding, the first shim 10 and the second shim 20 can also participate in the laser cladding, thickening the thin-walled defect of the blade so that it can match the laser cladding spot range. This allows sub-millimeter-level thin-walled blades to be repaired using laser cladding technology, improving the repair effect without the need for a spot cutting device or an automatic spot adjustment system, thus saving costs.

[0030] Furthermore, the first clamp 40 and the second clamp 50 can provide mounting positions for the first shim 10 and the second shim 20. For example, the first clamp 40 and the second clamp 50 can clamp the damaged blade 1 near the damaged surface, thus allowing the first shim 10 and the second shim 20 to be made smaller, saving costs. Also, the first clamp 40 and the second clamp 50 can fix the blade body near the repair end, facilitating stable clamping of the blade during the repair process. After the damaged blade 1 is repaired, the first clamp 40 and the second clamp 50 can be removed and reused for repairing other similar damaged blades.

[0031] The first shim 10 and the second shim 20 can be designed according to the specific leaf shape on both sides of the defective surface of the damaged blade 1. Since the first shim 10 and the second shim 20 only need to be clamped near the defective surface of the damaged blade 1 and removed after laser cladding, the burden of subsequent grinding of the repaired blade can be reduced and the economy of the repair process can be improved by designing a suitable disposable first shim 10 and second shim 20. Moreover, it is possible to repair damaged blades 1 with different leaf shapes on both sides of the defective surface.

[0032] In one exemplary embodiment, reference is made to Figure 5As shown, the surface of the first clamp 40 used to clamp the damaged blade 1 can also be adapted to the blade shape on the blade head side, and the surface of the second clamp 50 used to clamp the damaged blade 1 can be adapted to the blade shape on the blade back side, which can make the damaged blade 1 clamped more firmly and less likely to damage the blade. In addition, the surfaces of the first clamp 40 and the second clamp 50 used to clamp the turbine blade can only be approximately matched to the two sides of the blade, and not completely identical in shape. When repairing damaged blades 1 of different shapes and specifications, it can accommodate changes in blade shape and be used multiple times without having to make the first clamp 40 and the second clamp 50 separately for each type of blade, thus improving the economy and versatility of the device.

[0033] Specifically, turbine blades are generally made of metal alloys, and the first shim 10 and the second shim 20 can be made of the same material as the damaged blade 1. For example, the damaged blade 1, the first shim 10, and the second shim 20 are all made of nickel-based single-crystal high-temperature alloys.

[0034] In one exemplary embodiment, the width of the first pad in the first direction is not less than 2 mm; the width of the second pad in the first direction is also not less than 2 mm, thereby increasing the cladding plane during laser cladding repair, making the diameter of the area to be repaired greater than or equal to the diameter of the laser spot, thus solving the problem of uneven energy distribution due to excessively large spot size.

[0035] In one exemplary embodiment of this disclosure, reference is made to Figure 6 As shown, the repair device for the damaged blade also includes a base 30, on which a mounting groove 31 is provided that conforms to the shape of the tenon 101 of the damaged blade 1. When repairing the damaged blade 1, the tenon 101 of the damaged blade 1 can be installed in the mounting groove 31 to fix the damaged blade 1. Furthermore, the base 30 can adjust the angle between the damaged surface and the horizontal plane. During laser cladding, the damaged surface can be adjusted to be parallel to the horizontal plane and located on the laser cladding work platform, making laser cladding more convenient.

[0036] In one exemplary embodiment of this disclosure, the first gasket 10 further has a first outer peripheral surface surrounding the first clamping surface, and the first outer peripheral surface is surrounded by a plurality of first side surfaces. The second gasket 20 further has a second outer peripheral surface surrounding the second clamping surface, and the second outer peripheral surface is surrounded by a plurality of second side surfaces. At least one first side surface and at least one second side surface are coplanar.

[0037] Specifically, both the first gasket 10 and the second gasket 20 can be Figure 4The wedge shape shown can have multiple sets of coplanar first and second side surfaces. When repairing the damaged blade 1 using the repair device of the exemplary embodiment of this disclosure, after the first and second clamping surfaces are attached to the corresponding positions of the damaged blade 1, the outer peripheral surfaces of each side surrounding the blade base and the blade back of the damaged blade 1 can be aligned with the aforementioned first and second side surfaces. This facilitates subsequent laser cladding repair and removal of excess material after repair. Furthermore, the melting speed of the laser cladding area is similar, making it less prone to defects during repair and resulting in better repair effects.

[0038] At least one first side and at least one second side are coplanar. This can mean that the first and second outer peripheral surfaces have the same shape in the first direction, i.e., all first sides correspond to a coplanar second side, and similarly, all second sides correspond to a coplanar first side. Alternatively, only some first sides may correspond to coplanar second sides, while the remaining first sides may not correspond to coplanar second sides. When repairing the damaged blade 1 using the repair device of the exemplary embodiment of this disclosure, it is only necessary to align the first side with the coplanar second side and the corresponding second side with the side edge of the damaged blade 1.

[0039] In one exemplary embodiment of this disclosure, the first clamp 40 has a first notch that matches the shape of the first outer peripheral surface of the first pad 10, so that the first pad 10 can be detachably connected to the first clamp 40; similarly, the second clamp 50 has a second notch that matches the shape of the second outer peripheral surface of the second pad 20, so that the second pad 20 can be detachably connected to the second clamp 50. When the damaged blade repair device also includes a base 30, and the mounting groove 31 on the base 30 is used to fix the damaged blade 1, the first clamp 40 and the second clamp 50 can be disposed at one end of the base 30 near the mounting groove 31 and spaced apart from the mounting groove 31, so as to further fix the part of the blade body near the repair end, making the clamping of the blade more stable.

[0040] In one exemplary embodiment of this disclosure, reference is made to Figure 4 As shown, both the first clamp 40 and the second clamp 50 can be approximated as cuboids, with two opposite faces in the first direction used to clamp the damaged blade 1, and each having a first notch for connecting the first gasket 10 and a second notch for connecting the second gasket 20. Figure 4Taking the direction shown as an example, the angle between the first repair surface 11 and the upper surface of the first clamp 40 is greater than 0° and less than 90°, and the first repair surface 11 and at least one first side adjacent to the first repair surface 11 protrude from the upper surface of the first clamp 40. Similarly, the angle between the second repair surface 21 and the upper surface of the second clamp 50 is greater than 0° and less than 90°, and the second repair surface 21 and at least one second side adjacent to the second repair surface 21 protrude from the upper surface of the second clamp 50, and the first repair surface 11 and the second repair surface 21 are coplanar.

[0041] When polishing the damaged area of ​​defective blade 1, refer to Figure 2 As shown, since the damaged areas are mostly located at the blade tip, after grinding, the defective surface is usually an oblique surface with a certain angle to both the top of the blade and the side. When repairing the defective blade 1 using the repair device of the exemplary embodiment of this disclosure, the first repair surface 11 and the second repair surface 21 are aligned with the defective surface. During the subsequent laser cladding process, the first repair surface 11, the second repair surface 21, and the defective surface melt simultaneously, forming a molten pool on the surface. This reduces the likelihood of defects during repair and results in a better repair effect. (Reference image: Repaired blade) Figure 3 As shown.

[0042] Of course, in other exemplary embodiments, the first repair surface 11 and the second repair surface 21 may also be recessed into the upper surface of the first clamp 40 and the upper surface of the second clamp 50, and this disclosure does not impose any special limitations on this. The angle between the first repair surface 11 and the upper surface of the first clamp 40, and the angle between the second repair surface 21 and the upper surface of the second clamp 50 may also be other cases. For example, if the damage to the missing leaf occurs at the leaf tip, the angle between the first repair surface 11 and the upper surface of the first clamp 40 may also be 0°, and the angle between the second repair surface 21 and the upper surface of the second clamp 50 may also be 0°.

[0043] According to a second aspect of this disclosure, a repair system for damaged blades is provided, with reference to... Figure 6 As shown, the device includes a repair apparatus for damaged blades, a heating mechanism 2, and a cladding mechanism 3. The repair apparatus for damaged blades can be any of the solutions described in the above exemplary embodiments, or a reasonable combination of the solutions described in the above exemplary embodiments, and will not be described in detail here. At least a portion of the heating mechanism is disposed adjacent to the repair apparatus for damaged blades, and at least a portion of the cladding mechanism 3 is located between the first gasket 10 and the second gasket 20.

[0044] Specifically, the heating mechanism can be a heating wire or an induction heating device, and at least a portion of the heating mechanism is arranged adjacent to the repair device for the damaged blade. For example, it can be a heating wire coiled around the outside of the first pad 10 and the second pad 20. (Refer to...) Figure 6As shown, the heating mechanism can heat the damaged blade 1 to be repaired, the first gasket 10, and the second gasket 20, ensuring that their internal crystal orientations are aligned. This facilitates a strong metallurgical bond between the newly formed area and the substrate of the damaged blade 1 to be repaired. Furthermore, the heating mechanism may also include a temperature control device made of a temperature sensor, capable of precisely controlling the heating temperature.

[0045] The cladding mechanism 3 may include a laser scanning device 301 and a powder feeding device 302, used for laser cladding repair of the damaged blade 1. When using the damaged blade repair system of the exemplary embodiment of this disclosure, refer to... Figure 6 As shown, at least a portion of the powder feeding device 302 should be located between the first pad 10 and the second pad 20, and add powder material for laser cladding to the defective surface.

[0046] In one exemplary embodiment, the repair system for the damaged blade also includes a heat preservation mechanism, such as a conformal copper alloy tube with internal cooling water flow, which works in conjunction with a thermocouple in the heating mechanism to provide gradient heat preservation for the damaged blade 1 sandwiched between the first gasket 10 and the second gasket 20. This can prevent excessive temperature difference on the damaged surface during laser cladding, which could lead to uneven crystal orientation and affect the repair effect. Alternatively, an inductor coil can also be used for heat preservation, and this disclosure does not impose any specific limitations on this method.

[0047] In one exemplary embodiment, the repair system for the damaged blade also includes a control system, such as an electronic device like a control host, which is connected to the heating mechanism 2, the cladding mechanism 3, and the heat preservation mechanism via wired or wireless means, and is used to control the temperature, cladding process parameters, etc.

[0048] The defective blade repair system of this exemplary embodiment can be used to repair defective blades 1 using laser cladding. During laser cladding, the first shim 10 and the second shim 20 can also participate in the laser cladding, thickening the thin-walled defective part of the blade so that it can match the laser cladding spot range. This allows sub-millimeter-level thin-walled blades to be repaired using laser cladding technology, improving the repair effect without the need for a spot cutting device or an automatic spot adjustment system, thus saving costs.

[0049] According to a third aspect of this disclosure, a method for repairing a damaged blade is provided, for repairing a damaged blade 1 using the aforementioned damaged blade repair system, with reference to the appendix. Figure 7 As shown, the method may include steps S710 to S790.

[0050] Step S710: Grind the damaged area of ​​the damaged blade 1 to form a damaged surface; Step S720: Generate a first pad 10 based on the leaf shape on the leaf basin side of the damaged surface, and generate a second pad 20 based on the leaf shape on the leaf back side of the damaged surface. Step S730: Make a first clamp based on the leaf shape on the leaf basin side of the damaged leaf, and make a second clamp based on the leaf shape on the leaf back side of the damaged leaf. Step S740: Clamp the damaged blade 1 between the first pad 10 and the second pad 20, with the first clamping surface and the second clamping surface in close contact with the damaged blade 1; Step S750: Connect the first washer to the first clamp, and connect the second washer to the second clamp; Step S760: Connect the first clamp and the second clamp to fix the first washer and the second washer; Step S770: Perform laser cladding repair on the damaged blade 1; Step S780: Remove the first clamp and the second clamp; Step S790: Machining and grinding the repaired defective blade 1 to make the defective blade 1 have the same shape as the undamaged blade.

[0051] Specifically, in step S710, mechanical grinding can be used to remove old wear-resistant blocks and brazing filler metal with out-of-tolerance dimensions on the working surface of the blade crown, as well as the relevant areas affected by the repair path, and grind out the aforementioned defective surface. In addition, it may also include cleaning the blade surface, especially the defective surface to be repaired, with organic solvents, such as using acetone to clean the working surface of the blade serrated crown and then drying it.

[0052] In step S720, a first pad 10 with a first clamping surface is generated based on the leaf shape on the leaf basin side of the damaged surface, and a second pad 20 with a second clamping surface is generated based on the leaf shape on the leaf back side of the damaged surface. The specific structures of the first pad 10 and the second pad 20 are described in detail here with reference to the exemplary embodiments of the damaged leaf repair device provided in this disclosure. The first pad 10 and the second pad 20 can be formed by casting or 3D printing, etc.

[0053] In step S730, a first clamp 40 is fabricated based on the leaf shape of the leaf basin side of the damaged leaf 1, and a second clamp 50 is fabricated based on the leaf shape of the leaf back side of the damaged leaf 1. This may include machining a first notch matching the first outer peripheral surface and a second notch matching the second outer peripheral surface on the first clamp 40 and the second clamp 50, respectively. The structures of the first clamp 40 and the second clamp 50 are described in detail here with reference to the exemplary embodiments of the damaged leaf repair device provided in this disclosure.

[0054] In one exemplary embodiment, the processing of the first gasket 10 and the second gasket 20 can also be performed after the processing of the first jig 40 and the second jig 50. For example, the first jig 40 and the second jig 50 are designed firstly based on the leaf shape on the leaf base side and the leaf shape on the leaf back side of the defective blade 1, and the first and second notches with regular shapes are ground out at corresponding positions on the first jig 40 and the second jig 50, corresponding to the defective edge of the defective blade 1. Then, the first gasket 10 and the second gasket 20 are cast according to the leaf shape on the leaf base side and the leaf shape on the leaf back side of the defective edge, as well as the shapes of the first and second notches. In one exemplary embodiment, the width of both the first and second notches in the first direction, i.e., the blade thickness direction, is not less than 2 mm. For example, the width of both the first and second notches in the first direction, i.e., the blade thickness direction, is 2.5 mm.

[0055] In steps S740 to S760, the tenon 101 of the damaged blade 1 can be clamped in the mounting groove 31 of the base 30, and the damaged surface to be repaired can be installed horizontally on the working platform of the cladding mechanism 3. The first shim 10 is pressed tightly against the blade basin side of the repair surface, and the second shim 20 is pressed tightly against the blade back side of the repair surface, and the first repair surface 11, the second repair surface 21 and the damaged surface are aligned. Then, the first notch of the first clamp 40 and the second notch of the second clamp 50 are aligned with the first shim 10 and the second shim 20 respectively, and the first clamp 40 and the second clamp 50 are connected to fix the first shim 10 and the second shim 20. In an exemplary embodiment, the first clamp 40 and the second clamp 50 are fixed by a threaded connector, which is convenient for disassembly and assembly.

[0056] In step S770, laser cladding repair of the damaged blade 1 may include: Heating the damaged blade 1; Add powder material of the same material as the defective blade 1 to the defective surface, and scan the defective surface with a laser so that part of the defective blade 1, part of the first gasket 10, part of the second gasket 20 and the powder material melt simultaneously; Cooling defective blade 1, first gasket 10 and second gasket 20.

[0057] Specifically, the damaged blade 1 can be heated by the aforementioned heating mechanism 2 to ensure uniform crystal orientation within it. Furthermore, laser cladding repair of the damaged blade 1 can also include gradient heat preservation using a heat preservation mechanism. This avoids excessive temperature differences on the damaged surface during laser cladding, which could lead to uneven crystal orientation and affect the repair effect, thereby ensuring the macroscopic mechanical properties of the blade.

[0058] Furthermore, the simultaneous laser scanning of the defective surface and the addition of powder material allows both the defective material and the powder material to melt, ensuring consistent crystal orientation. Specifically, during laser scanning, powder material is added to the surface of the defective surface to be repaired, causing portions of the defective blade 1, the first gasket 10, the second gasket 20, and the powder material to melt and fuse together, then rapidly cool and solidify to form a cladding layer. A multi-layer, multi-pass cladding process can be used to repair the defective blade 1 layer by layer. The powder material is the same as that of the defective blade 1.

[0059] In one exemplary embodiment, leaf-material powder with a particle size of -100 mesh to 300 mesh is used as the powder material for laser cladding repair. The laser cladding power is 300-800W, and the spot size is... The scanning speed is 5-8 mm / s, and the powder feed rate is 8.5-12.5 g / min. The cladding area should not exceed the area where the first gasket 10 and the second gasket 20 are located.

[0060] After achieving near-net-shape forming, in step S780, the bolts connecting the first clamp 40 and the second clamp 50 are unscrewed, and the first clamp 40 and the second clamp 50 are removed from the entire repair device. Since the first clamp 40 and the second clamp 50 are not damaged during the entire repair process, they can be reused after removal when repairing other similar damaged blades, making them universally applicable to the same type of damage to the blades.

[0061] In step S790, the repaired blade is machined and polished to restore its shape and size to its undamaged state.

[0062] In one exemplary embodiment, before machining, the repaired area may be kept warm for a period of time to reduce thermal stress between the repaired area and adjacent areas. During both the laser cladding process and the warming process, a protective gas can be activated to prevent oxidation of the blades. The protective gas can be an inert gas such as argon or nitrogen, or other chemically stable gases, which will not be detailed here.

[0063] The repaired blade can be machined, which may include first removing the more prominent parts of the first shim 10 and the second shim 20 that protrude from the blade by machining, and then grinding and reshaping to precisely adjust the dimensional accuracy of the repaired blade.

[0064] By implementing the defective blade repair method of the exemplary embodiments of this disclosure, it is possible to repair defective thin-walled blades in conjunction with the aforementioned defective blade repair system. During laser cladding, the first shim 10 and the second shim 20 can also participate in the laser cladding, thickening the thin-walled defective portion of the blade so that it can match the laser cladding spot range. This allows sub-millimeter-level thin-walled blades to be repaired using laser cladding technology, improving the repair effect without the need for a spot cutting device or an automatic spot adjustment system, thus saving costs.

[0065] Other embodiments of this disclosure will readily occur to those skilled in the art upon consideration of the specification and practice of the invention disclosed herein. This disclosure is intended to cover any variations, uses, or adaptations of this disclosure that follow the general principles of this disclosure and include common knowledge or customary techniques in the art not disclosed herein. The specification and examples are to be considered exemplary only, and the true scope and spirit of this disclosure are indicated by the appended claims.

[0066] It should be understood that this disclosure is not limited to the precise structures described above and shown in the accompanying drawings, and various modifications and changes can be made without departing from its scope. The scope of protection of this disclosure is limited only by the appended claims.

Claims

1. A device for repairing damaged blades, characterized in that, include: The first pad has a first clamping surface, which is adapted to the leaf shape of the leaf basin side of the defective leaf surface; The first pad has a first outer peripheral surface surrounding the first clamping surface, and the first outer peripheral surface is surrounded by a plurality of first side surfaces; The second gasket has a second clamping surface adapted to the leaf shape on the back side of the defective surface; the second gasket has a second outer peripheral surface surrounding the second clamping surface, and the second outer peripheral surface is formed by a plurality of second side surfaces; A first clamp, wherein the first pad is detachably connected to the side of the first clamp near the second clamp; the first clamp has a first top surface parallel to a first direction, a portion of the first pad protruding from the first top surface, and one of the plurality of first side surfaces includes a first repair surface, wherein the angle between the first repair surface and the first top surface is greater than or equal to 0° and less than 90°; The second clamp, wherein the second pad is detachably connected to the side of the second clamp near the first clamp; The second clamp has a second top surface that is parallel to the first direction, a portion of the second pad protrudes from the second top surface, and one of the plurality of second side surfaces includes a second repair surface, wherein the angle between the second repair surface and the second top surface is greater than or equal to 0° and less than 90°. The first clamp and the second clamp are arranged sequentially in the first direction, and the first clamp and the second clamp are connected. The first clamping surface and the second clamping surface are opposite to each other in the first direction. At least one first side surface and at least one second side surface are coplanar, and the first repair surface, the second repair surface and the damaged surface are coplanar.

2. The device for repairing damaged blades according to claim 1, characterized in that, The width of the first gasket in the first direction is not less than 2mm; The width of the second gasket in the first direction is not less than 2 mm.

3. The device for repairing damaged blades according to claim 1, characterized in that, The device also includes a base, one end of which near the first clamp and the second clamp is provided with a mounting groove adapted to the tenon shape of the damaged blade.

4. The device for repairing damaged blades according to any one of claims 1 to 3, characterized in that, The first and second gaskets are made of the same material as the damaged blade.

5. A repair system for damaged blades, characterized in that, include: The device for repairing damaged blades as described in any one of claims 1 to 4; A heating mechanism is provided adjacent to the repair device for the damaged blade; A cladding mechanism, at least a portion of which is located between the first gasket and the second gasket.

6. A method for repairing damaged leaves, characterized in that, For repairing damaged blades using the damaged blade repair system of claim 5, the method for repairing the damaged blades includes: Grind the damaged area of ​​the defective blade to form the defective surface; The first pad is generated according to the leaf shape on the leaf basin side of the defective surface, and the second pad is generated according to the leaf shape on the leaf back side of the defective surface. The first clamp is made according to the leaf shape on the leaf basin side of the damaged leaf, and the second clamp is made according to the leaf shape on the leaf back side of the damaged leaf; The damaged blade is clamped between the first pad and the second pad, with the first clamping surface and the second clamping surface in close contact with the damaged blade; Connect the first washer to the first clamp, and connect the second washer to the second clamp; Connect the first clamp and the second clamp to fix the first gasket and the second gasket; The damaged blades were repaired by laser cladding. Remove the first clamp and the second clamp; The damaged blade is machined and polished to make its shape consistent with that of the undamaged blade; The method further includes clamping the damaged blade between the first pad and the second pad, with the first clamping surface and the second clamping surface in close contact with the damaged blade, and also includes: A first notch that matches the first outer peripheral surface is machined on the first fixture; A second notch that matches the second outer peripheral surface is machined on the second fixture; The first clamping surface is tightly attached to the leaf basin side of the defective surface, the first repair surface is aligned with the defective surface, and at least two of the first side surfaces are in contact with the first notch. The second clamping surface is pressed tightly against the leaf back side of the defective surface, the second repair surface is aligned with the defective surface, and at least two of the second side surfaces are in contact with the second notch.

7. The method for repairing damaged blades according to claim 6, characterized in that, Laser cladding repair of the damaged blades includes: Heating the damaged blade; Add a powder material identical to the material of the damaged blade to the damaged surface, and then scan the damaged surface with a laser to simultaneously melt a portion of the damaged blade, a portion of the first gasket, a portion of the second gasket, and the powder material. Cool the damaged blade, the first gasket, and the second gasket.

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