Gas Turbine Blade Tip Laser Repair Without Engine Disassembly
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Solution Overview
Problem
Conventional repair methods for gas turbine engines require disassembly and removal from aircraft, leading to increased time and costs due to the need for external maintenance.
Innovation Solution
A system and method for in situ repair of internal components using a repair tool inserted through access ports, which supplies new material and directs a laser to fuse the material to the component, allowing for precision repairs without disassembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of repair
If conventional repair methods are used, then the engine can be repaired, but the engine must be removed from the aircraft and disassembled, resulting in increased time and costs
Solution Approach 1:
The repair system enables the engine to be repaired in its installed position on the aircraft without requiring removal or disassembly. The laser welding apparatus and material delivery system are designed to access the turbine blade through existing engine structures, allowing the engine to service itself in place.
Solution Approach 2:
A flexible delivery system with articulated segments acts as an intermediary to navigate the repair tools and materials through the engine's internal passages and access ports to reach the turbine blade defect location, enabling in-situ repair without disassembly.
2Ease of repair
If conventional repair methods are used, then the engine can be repaired, but the engine must be removed from the aircraft and disassembled, resulting in increased costs
Solution Approach 1:
The engine is repaired in its installed position on the aircraft, eliminating the need for costly removal, handling, and reinstallation operations. The system allows the engine to be maintained in place, reducing labor costs and facility requirements associated with conventional off-wing repair.
3Loss of time
If in situ repair is performed, then maintenance time is reduced, but the repair tool must be inserted through access ports and navigate within the engine
Solution Approach 1:
The delivery system is divided into multiple articulated segments or joints that can bend and flex to navigate the complex internal geometry of the engine. This segmented structure allows the tool to reach difficult-to-access defect locations while maintaining a relatively simple overall design.
Solution Approach 2:
The repair tools and materials are delivered through a nested, telescoping delivery system that can be inserted through existing engine access ports. The system uses concentric or nested structures to pack complex repair equipment into a compact form that can pass through limited access openings.
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
Enables efficient and cost-effective in situ repair of gas turbine engine components, reducing downtime and maintenance costs by allowing repairs to be performed while the engine remains assembled.
Implementation Method 1
directing a laser onto the interface of the material supply and the tip such that the material supply melts and attaches to the tip
Implementation Method 2
the material supply melts and attaches to the tip
Implementation Method 3
directing a laser to the new material within the fillable area to fuse the new material to the component within the defect
Data Source
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AI summary
Methods for material build-up on a tip 200 of a blade of a gas turbine engine 10 are provided. The method can include inserting a material supply adjacent to the tip 200 and directing a laser 109 onto the interface of the material supply and the tip 200 such that the material supply melts and attaches to the tip 200. Methods are also provided for remotely stopping a crack 106 in a component 104 of a gas turbine engine 10. The method can include inserting an integrated repair interface attached to a cable delivery system within a gas turbine engine; positioning the tip adjacent to a defect 106 within a surface of the component 104; supplying a new material to the fillable area to fill the defect 106; and directing a laser 109 to the new material within the fillable area to fuse the new material to the component 104 within the defect 106.