Additive Blade Extension Printing With In-Situ Interface Alignment

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Solution Overview

Problem

Current methods for additively printing extension segments on turbomachine blades, such as those in gas turbine engines, face challenges in accurately aligning the printed segments due to separate measurement systems, leading to potential misalignment and extensive rework or scrapping of workpieces.

Innovation Solution

An additive manufacturing system and method that uses a computing system to control a print head to scan a workpiece interface with an electromagnetic radiation beam, determining the location of the interface based on reflections and beam data, allowing for precise alignment and printing of extension segments directly on the workpiece within the same machine.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Measurement precision

If separate measurement systems are used to determine workpiece interface location, then measurement can be performed, but alignment precision deteriorates due to position consistency issues between measurement and printing systems

Engineering Contradiction:

Improveworkpiece interface location detectionVSAvoidextension segment alignment

Core Design Contradiction:

Measurement precisionVSManufacturing precision

Solution Approach 1:

The patent merges the measurement function and additive printing function into a single integrated system. The build plate serves dual purposes: as a measurement platform where the electromagnetic radiation beam scans to detect the workpiece interface location, and as a printing platform where the print head deposits material. This integration eliminates the need to transfer workpieces between separate measurement and printing systems, ensuring position consistency and resolving the alignment precision issue.

Inventive Principle:

Principle #5Merging (Combining)

2Adaptability or versatility

If the workpiece position changes between separate measurement and printing operations, then flexibility is improved, but alignment precision deteriorates

Engineering Contradiction:

Improveworkpiece handling flexibilityVSAvoidextension segment alignment

Core Design Contradiction:

Adaptability or versatilityVSManufacturing precision

Solution Approach 1:

By combining measurement and printing operations in a single integrated system, the workpiece remains on the build plate throughout the entire process. The system maintains position consistency by performing both scanning and printing operations from the same reference frame, eliminating alignment errors caused by workpiece repositioning while preserving operational flexibility.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The system uses real-time feedback from the electromagnetic radiation beam scanning process to detect the actual workpiece interface location. This measurement data is immediately used to guide the print head positioning, creating a closed-loop control system that ensures precise alignment based on actual workpiece geometry rather than pre-programmed positions.

Inventive Principle:

Principle #23Feedback

3Manufacturing precision

If integrated scanning and printing is implemented, then alignment precision is improved, but device complexity increases

Engineering Contradiction:

Improveextension segment alignmentVSAvoidadditive manufacturing system

Core Design Contradiction:

Manufacturing precisionVSDevice complexity

Solution Approach 1:

The build plate is designed as a multi-functional component that serves both as a measurement platform for the electromagnetic radiation beam scanning system and as a printing platform for the print head. This universal component reduces overall system complexity by eliminating the need for separate measurement and printing fixtures, while still achieving integrated scanning and printing capabilities.

Inventive Principle:

Principle #6Universality (Multi-functionality)

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 accurate alignment and reduces rework by maintaining the workpiece's position consistency between scanning and printing, enhancing the precision and efficiency of additively printing extension segments on turbomachine blades.

Implementation Method 1

receiving data associated with reflections of the electromagnetic radiation beam off of the build plate

Methodology Applied

Scientific EffectReflection: Reflection

Implementation Method 2

an extension segment is additively printed on the determined workpiece interface

Methodology Applied

Scientific EffectAdditive manufacturing: 3D Printing

Data Source

PatentUS11691336B2System and method for additively printing extension segments on workpieces

Publication Date: 2023.07.04 GENERAL ELECTRIC CO

AI summary

A method for additively printing extension segments on workpieces using an additive manufacturing machine includes controlling, with a computing system, an operation of a print head of the machine such that a region of interest of a build plate of the machine is scanned with an electromagnetic radiation beam. Additionally, the method includes receiving, with the computing system, data associated with reflections of the beam off of the build plate as the region interest is scanned. Furthermore, the method includes receiving, with the computing system, data associated with a location of the beam relative to the build plate. Moreover, the method includes determining, with the computing system, a location of a workpiece interface based on the received data. In addition, the method includes controlling, with the computing system, the operation of the print head such that an extension segment is additively printed on the determined workpiece interface.