Adaptive Toolpath Repair for Additive-Machined Components
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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 repair processes are not fully optimized for precision and material efficiency.
Innovation Solution
A method involving additive manufacturing using structured light scanning to determine toolpaths for both additive and machining processes, where powder is deposited and melted to repair defects, and then excess material is removed to restore the component to its original specifications, utilizing different powders for filling voids and providing claddings based on their properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of substance
If additive manufacturing is used to repair components, then material efficiency and precision are improved, but device complexity and process complexity increase
Solution Approach 1:
The patent combines multiple manufacturing processes (additive manufacturing, machining, inspection) into an integrated adaptive manufacturing system. The system merges material deposition, melting, and removal operations into a unified workflow that shares common infrastructure including the build chamber, heating elements, and control systems, thereby reducing overall device complexity despite the advanced capabilities required.
Solution Approach 2:
The additive manufacturing device is designed with multi-functionality, serving both as a material deposition system and a heating source for melting powder. The same build chamber and positioning system are used for both additive manufacturing and subsequent machining operations, eliminating the need for separate dedicated equipment and reducing overall system complexity.
2Manufacturing precision
If adaptive manufacturing with structured light scanning is used, then manufacturing precision is improved, but measurement and detection difficulty increase
Solution Approach 1:
The system performs preliminary scanning and measurement of the component's actual geometry before beginning additive manufacturing or machining operations. This preliminary action captures the as-built conditions and deviations, allowing the adaptive control system to plan compensatory operations that ensure final dimensional accuracy while simplifying real-time measurement requirements during execution.
Solution Approach 2:
The adaptive manufacturing system implements continuous feedback loops where structured light scanning data is compared against target geometry, and deviations are used to adjust subsequent material deposition or removal operations. This feedback mechanism automates the correction of measurement uncertainties and maintains manufacturing precision without requiring complex manual intervention.
3Reliability
If multiple powders are used for different repair needs, then repair effectiveness is improved, but process complexity increases
Solution Approach 1:
The repair process is segmented into distinct operational phases, each utilizing specific powder types as needed. The system divides the build chamber into zones or sequences where different powders are introduced only when required for specific repair tasks (void filling vs. cladding), simplifying material handling by avoiding the need to manage all powder types simultaneously in a single operation.
Solution Approach 2:
The system changes material parameters (powder type, composition, properties) dynamically based on the specific repair requirements detected during scanning and planning. By adjusting material parameters rather than using fixed material setups, the system achieves versatile repair effectiveness while maintaining relatively simple material handling through programmed parameter changes rather than physical system reconfiguration.
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 allows for precise repair and manufacturing of components by accurately determining the amount and type of material needed, ensuring effective filling of defects and restoration of dimensions, thereby reducing material waste and costs while maintaining component performance.
Implementation Method 1
depositing powder using an additive manufacturing device based upon additive manufacturing data to provide a first object, the additive manufacturing device melting the powder
Data Source
AI summary
A method of manufacturing a component includes a) depositing powder using an additive manufacturing device based upon additive manufacturing data to provide a first object, the additive manufacturing device melting the powder, b) determining predicted characteristics of the first object based upon the additive manufacturing data developed in step a), c) comparing the predicted characteristics of the first object to the reference data to provide machining data and d) machining the first object using the machining data. A system for manufacturing a component is also disclosed.