Blisk Blade Repair Shield for Additive Spatter Containment
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Solution Overview
Problem
The existing methods for repairing bladed disks, such as blisks, in gas turbine engines face challenges with material spatter during additive manufacturing processes, which can damage neighboring blades and increase manufacturing costs due to inadequate shielding.
Innovation Solution
A shield member is positioned around the perimeter of a partial blade during the additive manufacturing process to prevent spatter from depositing on adjacent areas, using materials with high thermal conductivity or ceramic components to manage heat and prevent contamination, and potentially incorporating cooling passageways to control temperature.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If additive manufacturing process is used to repair bladed disks, then manufacturing efficiency and precision are improved, but material spatter damages neighboring blades and increases manufacturing costs
Solution Approach 1:
A shield member is positioned between the additive manufacturing process and the surrounding blades to intercept and contain material spatter. The shield member acts as an intermediary barrier that protects neighboring blades from contamination while allowing the repair process to proceed with high precision.
Solution Approach 2:
The shield member is pre-positioned around the partial blade before the additive manufacturing process begins. This preliminary protective action prevents spatter from reaching neighboring blades before damage can occur, eliminating the need for subsequent cleaning or repair of contaminated areas.
2Object-affected harmful factors
If shield member is added to prevent spatter, then protection of neighboring blades is improved, but device complexity increases
Solution Approach 1:
The shield member is designed as a thin-walled structure that provides effective spatter protection without adding significant mass or complexity. The thin-film approach maintains structural simplicity while achieving the protective function, avoiding the need for complex heavy-duty shielding systems.
Solution Approach 2:
The shield member is divided into multiple segments or sections that can be independently positioned and removed. This segmentation simplifies the overall system by allowing the shield to be assembled and disassembled easily, reducing the complexity of handling and positioning a single large complex shield structure.
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
The shield member effectively prevents spatter from damaging other parts of the blisk, reduces manufacturing costs by minimizing material waste, and ensures the integrity of the blisk by maintaining temperature control during the repair process.
Implementation Method 1
using materials with high thermal conductivity or ceramic components to manage heat and prevent contamination
Implementation Method 2
depositing, with the shield member around the perimeter of the partial blade, a material on the build surface using an additive manufacturing technique
Data Source
AI summary
In some examples, systems and techniques for repairing or otherwise forming a blade of a bladed disk. In one example, a method including positioning a shield member around a perimeter of a partial blade extending from a rotor disk of a bladed disk, the shield member being positioned adjacent to a build surface of the partial blade; and depositing, with the shield member around the perimeter of the partial blade, a material on the build surface using an additive manufacturing technique to form a repaired portion on the build surface of the partial blade.