Adaptive Component Overhaul with CT Repair and Light-Scan Machining
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Solution Overview
Problem
Complex components, such as those in gas turbine engines, require efficient repair methods to address defects and wear without the high costs associated with replacement, as existing braze and weld filler application processes are not fully optimized.
Innovation Solution
A method involving computed tomography scanning to generate additive manufacturing toolpaths, followed by structured light scanning to determine machining toolpaths, using distinct braze powders for filling voids and forming claddings, and subsequent machining to restore the component to its original specifications.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional braze and weld filler application processes are used to repair defects, then repair capability is provided, but manufacturing precision and process optimization are insufficient
Solution Approach 1:
The method performs preliminary scanning and analysis of the component using computed tomography before repair to create a digital model and identify defects. This preliminary action enables precise planning of the repair process, allowing for optimized toolpaths and material deposition strategies that improve manufacturing precision while reducing overall process complexity through advance preparation
Solution Approach 2:
The invention replaces conventional mechanical braze and weld filler application processes with additive manufacturing technology that deposits material layer-by-layer based on digital models. This substitution enables precise control over material placement, improving repair precision while the automated additive process reduces the complexity associated with manual conventional repair methods
2Reliability
If component replacement is performed instead of repair, then reliability is restored, but cost increases significantly
Solution Approach 1:
The method recovers the value of the existing component by repairing it through additive manufacturing rather than discarding and replacing it. The process removes defective material, deposits new material to restore functionality, and returns the component to service, thereby maintaining reliability while avoiding the cost of replacement and reducing material waste
Solution Approach 2:
The invention changes the physical and chemical parameters of the component by depositing new material with controlled composition, temperature, and microstructure through additive manufacturing. This allows the component to regain its original reliability properties while using less total material than replacement would require, thus reducing cost
3Manufacturing precision
If computed tomography scanning is used to generate additive manufacturing toolpaths, then manufacturing precision improves, but measurement time increases
Solution Approach 1:
The computed tomography scanning is performed as a preliminary action before the actual repair process to create a comprehensive digital model of the component's internal and external geometry. This advance scanning, though time-consuming, enables highly accurate toolpath generation for subsequent additive manufacturing, improving manufacturing precision while the one-time nature of the scan amortizes the time cost over the entire repair process
Solution Approach 2:
The computed tomography scan creates a precise digital copy or virtual model of the physical component, including its defects and geometry. This digital copy can be reused for planning and simulation without requiring additional physical scanning time, while still providing the precision needed for accurate toolpath generation in the actual repair process
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 precise repair of complex components by accurately depositing and removing materials, effectively extending the life of components like those in gas turbine engines while reducing replacement costs.
Implementation Method 1
scanning a component using computed tomography to provide first scanned data
Implementation Method 2
scanning the first object using structural light scan to provide second scanned data
Implementation Method 3
depositing material on the component using an additive manufacturing device based upon the additive manufacturing data to provide a first object
Data Source
Figure 1A~1B
Figure 2A~2B
Figure 2C
AI summary
A method of overhaul of a component includes a) scanning a component (20) using computed tomography to provide first scanned data, b) comparing the first scanned data to reference data to provide additive manufacturing data, c) depositing material on the component using an additive manufacturing device (24) based upon the additive manufacturing data to provide a first object, d) scanning the first object using a structured light scan (103) to provide second scanned data, and determining predicted characteristics of the first object based upon the second scanned data of step d), e) comparing the predicted characteristics of the first object to the reference data to provide machining data and f) machining the first object using the machining data. A system (99) for overhauling the component is also disclosed.