Airfoil Cluster Repair Using Register Blocks
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Solution Overview
Problem
Current repair methods for airfoil clusters in gas turbine engines do not account for features like endwall contouring and serpentine passages, leading to challenges in precise alignment and effective repair.
Innovation Solution
The method involves attaching register blocks to the airfoil clusters, machining a datum system on these blocks for precise alignment, removing damaged portions using wire EDM, and joining salvaged parts through diffusion brazing to form a new, functional airfoil cluster while preserving the integrity of the serpentine passages.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of repair
If current repair methods are used to cut and join airfoil clusters, then damaged parts can be replaced, but precise alignment of features like endwall contouring and serpentine passages cannot be achieved
Solution Approach 1:
Register blocks are attached to the airfoil clusters before the repair process begins. These blocks contain pre-machined datum surfaces that establish precise reference planes for alignment. By preparing these alignment features in advance, the patent enables accurate repositioning of salvaged airfoil clusters to match the original geometry of serpentine passages and endwall contouring.
Solution Approach 2:
The register blocks serve as intermediary elements between the salvaged airfoil clusters and the engine structure. These blocks provide standardized attachment and alignment interfaces that mediate the joining process, ensuring that complex features like serpentine passages and endwall contouring align precisely without requiring direct measurement and matching of the airfoil clusters themselves.
2Loss of substance
If salvaged parts are used for repair, then cost savings are achieved, but ensuring precise alignment and structural integrity becomes more difficult
Solution Approach 1:
The airfoil cluster assembly is segmented into removable portions, with register blocks attached to facilitate independent handling and repositioning of salvaged segments. This segmentation allows damaged portions to be replaced while preserving intact sections, maximizing material utilization while maintaining precise alignment through the register block interface.
Solution Approach 2:
The patent enables recovery and reuse of salvaged airfoil clusters by providing a systematic method for their reattachment. Rather than discarding damaged clusters entirely, the register block system allows selective replacement of only the damaged portions while recovering and reusing intact salvaged sections, reducing material loss while ensuring proper alignment through standardized datum surfaces.
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 ensures precise alignment and attachment of airfoil clusters, maintaining unimpeded airflow and supporting engine performance, while offering cost-saving benefits by utilizing salvaged parts.
Implementation Method 1
removing damaged portions with respect to the location of the serpentine passages using a wire electrical discharge machining process
Implementation Method 2
joining the first and second airfoil clusters using a diffusion brazing process
Data Source
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AI summary
A method for working an airfoil cluster is disclosed. The method may include attaching a first datum to a first portion of the airfoil cluster, and joining a second portion of the airfoil cluster to the first portion, the second portion having a second datum substantially aligned with the first datum in a common plane spaced away from the first and second portions.