Turbine Blade Tip Coating Repair With Partial Stripping
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Solution Overview
Problem
Armored turbine blades with blade coatings can only be repaired a few times due to material loss from stripping, leading to high costs and reduced service life, as current methods involve numerous expensive process steps and result in loss of wall thickness and strength.
Innovation Solution
A method that involves removing only a part of the blade tip armor and coating near the damaged area, applying repair material through welding or additive manufacturing, and restoring the original contour with minimal heat-affected zone, allowing for cost-effective and frequent repairs without complete stripping and recoating.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If complete stripping and recoating of the turbine blade is performed, then the blade coating is fully restored, but material loss occurs leading to reduced wall thickness and strength
Solution Approach 1:
The blade is divided into two zones: a repair zone where coating is removed and restored, and a preservation zone where original coating is retained. This segmentation allows localized repair without complete stripping, preventing material loss while restoring coating integrity in the damaged area.
Solution Approach 2:
The repair process applies different treatments to different regions of the blade. The repair zone undergoes coating removal and restoration, while the preservation zone maintains its original coating. This local quality approach ensures coating restoration where needed without unnecessary material removal elsewhere.
2Reliability
If complete stripping and recoating is performed, then the blade coating is fully restored, but repair time and costs increase significantly
Solution Approach 1:
The repair process is segmented into localized steps confined to the repair zone, eliminating time-consuming complete stripping and recoating operations. Only the damaged area undergoes treatment, significantly reducing repair time while maintaining coating restoration effectiveness.
Solution Approach 2:
Instead of performing complete stripping and recoating (excessive action), the method applies partial action limited to the repair zone. This partial approach achieves sufficient coating restoration without the time penalty of full blade processing.
3Duration of action of stationary object
If multiple repairs are performed on armored turbine blades, then service life is extended, but wall thickness and strength are compromised due to repeated material removal
Solution Approach 1:
By segmenting the blade into repair and preservation zones, the method enables repeated repairs in the same localized area without requiring progressive stripping across the entire blade. This confines material removal to minimal necessary amounts, preserving overall blade strength while extending service life through multiple repair cycles.
Solution Approach 2:
The method uses partial action (localized repair) instead of excessive action (complete stripping), allowing multiple repairs to be performed on the same blade without cumulative strength loss. Each repair removes only the minimum necessary material in the repair zone, preserving blade integrity for future repair cycles.
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 extends the service life of turbine blades by reducing material loss and repair costs, improving running time behavior, and enabling multiple repairs without significant loss of strength or wall thickness, thus saving time and resources.
Implementation Method 1
a welding device which is designed to apply a repair material to the repair surface by a welding process
Implementation Method 2
an additive manufacturing device which is designed to apply a repair material to the repair surface by an additive manufacturing process
Data Source
AI summary
The invention relates to a method for repairing a damaged blade tip of an armored turbine blade, provided with a blade coating, of a thermal gas turbine. The method according to the invention comprises the steps of removing a blade tip armor of the turbine blade at least in the area of the damaged blade tip and producing a repair surface (12), removing only part of the blade coating of the turbine blade in the area of the repair surface while retaining a part of the blade coating (14) at a distance from the repair surface , restoring the blade tip armor (20) and restoring the blade coating in the area of the repaired blade tip (22). The invention also relates to a device for carrying out such a method.