Adaptive Braze Powder Deposition Using CT Data for Defect Repair
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Solution Overview
Problem
Existing manufacturing processes for components, such as those in gas turbine engines, face challenges in reducing material waste and secondary defects, particularly in the application of braze material and weld filler, which can lead to inefficiencies and suboptimal results.
Innovation Solution
The method involves using computed tomography to scan substrates, comparing scan data to reference data to generate additive manufacturing data, and depositing braze powder which is then sintered and diffusion-bonded to the substrate using a laser, allowing for precise repair and reduction of defects with minimal waste.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional braze material application processes are used, then defects can be repaired, but material waste increases and secondary defects are formed
Solution Approach 1:
The patent applies braze material selectively only to the specific defect locations identified by CT scanning, rather than applying material uniformly across the entire component. The additive manufacturing system deposits braze powder precisely where needed based on the scanned defect geometry, ensuring local repair quality while minimizing material waste.
Solution Approach 2:
The patent performs CT scanning and defect analysis before the braze material application process. By identifying and characterizing defects in advance, the system can plan the exact material deposition path and quantity needed, preventing both material waste and secondary defects from improper application.
2Reliability
If traditional braze material application processes are used, then defects can be repaired, but secondary defects are formed
Solution Approach 1:
The patent uses CT scanning to obtain real-time feedback on the substrate's internal structure and defect characteristics. This feedback information guides the additive manufacturing process, allowing the system to adjust material deposition parameters dynamically to achieve proper filler geometry and avoid creating secondary defects such as excessive material buildup or improper penetration.
Solution Approach 2:
The patent modifies the filler geometry parameters based on the specific defect characteristics identified through CT scanning. By adjusting parameters such as filler volume, distribution density, and spatial configuration to match the actual defect geometry, the system achieves optimal repair quality without generating secondary defects.
3Measurement precision
If computed tomography scanning is performed to obtain substrate data, then precise defect identification is achieved, but process complexity increases
Solution Approach 1:
The patent employs a multi-functional integrated system where the CT scanner serves multiple purposes: defect detection, defect characterization, and process monitoring. The same scanning technology that identifies defects also provides geometric data for repair planning and verifies repair quality, reducing the need for separate measurement systems and justifying the initial complexity through multiple uses.
4Manufacturing precision
If additive manufacturing with sintering is used to deposit braze powder, then material precision is improved, but process time increases
Solution Approach 1:
The patent utilizes the phase transition of braze powder from solid to sintered state through controlled heating. By leveraging the sintering process efficiently with optimized temperature profiles and atmospheric control, the system achieves precise material deposition and bonding without excessive process time, transforming the time-consuming aspect into a controlled phase change operation.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach enables the efficient repair of defects with reduced material consumption and minimization of secondary defects, improving the quality and reliability of components by using sintered braze material to fill voids and form claddings, thus enhancing the substrate's structural integrity.
Implementation Method 1
a substrate is scanned using computed tomography to provide substrate scan data
Implementation Method 2
The braze powder is sintered together using a laser beam during the depositing of the braze powder
Implementation Method 3
The sintered braze material is heated to melt the sintered braze material and to diffusion bond the sintered braze material to the substrate
Data Source
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AI summary
A method is disclosed for providing a component (22). During this method, a substrate (46) is scanned using computed tomography to provide substrate scan data. The substrate scan data is compared to substrate reference data to provide additive manufacturing data. Braze powder (44A) is deposited with the substrate (46) based on the additive manufacturing data. The braze powder (44A) is sintered together during the depositing of the braze powder (44A) to provide the substrate (46) with sintered braze material (66A). The sintered braze material (66A) is heated to melt the sintered braze material (66A) and to diffusion bond the sintered braze material (66A) to the substrate (46).