Airfoil Repair Joining for Precise Weld Alignment
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Solution Overview
Problem
Existing methods for repairing damaged airfoils in gas turbine engines, such as those with dovetail configurations or blisks, are costly and time-consuming, often requiring complete replacement of the airfoil or risking damage to adjacent components during repair.
Innovation Solution
The use of an oversized airfoil repair component with a repair attachment section that aligns and secures to a cropped airfoil, utilizing an electrode assembly for precise alignment and welding, reducing the need for hand tools and improving joint quality.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If existing repair methods are used for damaged airfoils, then complete replacement or extensive manual repair is required, but this increases cost and time consumption
Solution Approach 1:
The invention divides the airfoil into a base airfoil portion and a separate repair component that can be attached to replace only the damaged section. This segmentation allows selective repair rather than complete replacement, improving efficiency by focusing only on the damaged area and reducing repair time.
Solution Approach 2:
The repair component is pre-manufactured with the correct geometry and attachment features before the repair process. This preliminary preparation eliminates the need for extensive on-site manufacturing or shaping during repair, thereby increasing repair efficiency and reducing the time required to complete the repair operation.
2Productivity
If existing repair methods are used for damaged airfoils, then complete replacement or extensive manual repair is required, but this increases cost
Solution Approach 1:
By segmenting the airfoil into replaceable portions, the invention allows repair of only the damaged section rather than replacing the entire airfoil. This significantly reduces material waste and repair costs while maintaining structural integrity through the specialized attachment mechanism.
Solution Approach 2:
The invention enables discarding only the damaged portion of the airfoil while recovering and retaining the undamaged base airfoil structure. This selective replacement approach reduces overall material consumption and repair costs compared to complete airfoil replacement.
3Manufacturing precision
If existing repair methods are used for damaged airfoils, then manual tools and extensive processing are required, but this increases complexity and reduces joint quality
Solution Approach 1:
The invention replaces complex manual alignment and joining operations with a specialized attachment mechanism that features pre-configured alignment elements and a simplified joining process. This substitution reduces process complexity while ensuring consistent, high-quality joints through the designed attachment geometry.
Solution Approach 2:
The repair component includes self-aligning features such as protrusions that fit into corresponding recesses on the base airfoil, enabling automatic alignment during attachment. This self-service alignment mechanism eliminates the need for complex external alignment tools and procedures, reducing process complexity while maintaining high joint quality.
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 method enhances repair efficiency and yield while minimizing costs and complexity by ensuring accurate alignment and reducing the need for extensive post-joining processing, thus improving the quality and speed of airfoil repairs.
Implementation Method 1
utilizing an electrode assembly for precise alignment and welding
Data Source
AI summary
An airfoil component for attaching to a cropped airfoil is provided. The cropped airfoil comprises a cropped airfoil attachment section and a cropped first side opposite a cropped second side, which each extend axially between a cropped first edge and a cropped second edge to define a cropped chord length. The airfoil component comprises a body having a component first side opposite a component second side. The body defines an attachment section for attaching the airfoil component to the cropped airfoil at the cropped airfoil attachment section. The attachment section extends axially between a component first edge and a component second edge to define a component chord length, and the attachment section is oversized with respect to the cropped airfoil attachment section such that the component chord length is longer than the cropped chord length. Systems and methods also are provided.