AM Engine Conduit Inspection Using Frozen Plugging Media
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Solution Overview
Problem
Non-destructive inspection of internal conduits in components fabricated via additive manufacturing processes, such as fuel rails in gas turbine engines, is challenging due to the complexity and internal nature of these components.
Innovation Solution
A method involving a fluid-blocking header with a conformal surface that mates with the component's external surface, freezing a plugging media within the conduit, and analyzing fluid flow characteristics at the outlet to detect blockages, using cooling systems like fluid coolers or thermoelectric coolers to facilitate the process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If additive manufacturing is used to fabricate components with internal conduits, then cost and weight savings are achieved, but non-destructive inspection of conduit integrity becomes challenging
Solution Approach 1:
A plugging media is introduced as an intermediary substance to fill the internal conduits, enabling indirect detection of conduit integrity. The plugging media serves as a mediator between the inspection system and the concealed conduits, allowing flow characteristics to reveal blockage conditions without direct visual access
Solution Approach 2:
The patent replaces complex mechanical inspection methods with a fluid-based detection system. Instead of using mechanical probes or visual inspection equipment, the system uses fluid flow characteristics (pressure, flow rate) to detect conduit blockages, simplifying the inspection mechanism
2Ease of operation
If conventional inspection methods are used on internal conduits, then inspection simplicity is maintained, but inspection effectiveness deteriorates due to internal conduit complexity
Solution Approach 1:
The patent applies hydraulic principles by using fluid flow through the conduits to detect blockages. By analyzing pressure and flow rate characteristics of the fluid moving through the internal conduits, the system reliably detects obstructions while maintaining operational simplicity
Solution Approach 2:
The system detects conduit blockages by monitoring changes in fluid flow parameters (pressure, flow rate) rather than attempting direct visual or physical access to the conduits. This parameter-based detection method maintains inspection simplicity while improving effectiveness
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
Effectively assesses blockages within internal conduits of components made via additive manufacturing, ensuring the integrity and functionality of fuel systems in gas turbine engines, enhancing reliability and cost-effectiveness.
Implementation Method 1
activating the fluid-blocking header to freeze the plugging media in a vicinity of the fluid-blocking header
Data Source
AI summary
A method for inspecting a component made using an additive manufacturing process, the component having an internal conduit, is disclosed. In various embodiments, the method includes the steps of: attaching a fluid-blocking header to the component, the fluid-blocking header having an internal conformal surface configured to mate with an external conformal surface of the component; introducing a plugging media into the internal conduit; activating the fluid-blocking header to freeze the plugging media in a vicinity of the fluid-blocking header; pressurizing the internal conduit of the component; and analyzing a fluid flow characteristic at an outlet of the component to assess an occurrence of a blockage within the internal conduit.