Structured Light Braze Cladding for Low-Waste Defect Repair
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Solution Overview
Problem
Existing manufacturing processes for components, such as those in gas turbine engines, face challenges in reducing material waste and secondary defects, and there is a need for improved methods to efficiently repair or overhaul components with minimal waste and defect formation.
Innovation Solution
The method involves scanning a substrate using structured light to generate additive manufacturing data, depositing and sintering braze powder to create sintered braze material, which is then diffusion-bonded to the substrate, either by heating in a furnace or within a void filled with braze slurry, to form a cladding and repair defects.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional braze filler material or weld filler processes are used, then component defects can be repaired, but material waste and secondary defects increase
Solution Approach 1:
The patent applies local quality by selectively depositing braze powder only in specific regions where defects are detected through scanning, rather than applying material uniformly across the entire component surface. This targeted approach ensures repair quality is maintained while minimizing material waste in areas that do not require repair.
Solution Approach 2:
The patent implements preliminary action by scanning the component substrate before repair to identify defect locations and characteristics. This pre-scan data is used to generate precise deposition paths and parameters, ensuring that braze material is applied only where needed and reducing both material waste and secondary defects from unnecessary heating or material application.
2Reliability
If traditional braze filler material or weld filler processes are used, then component defects can be repaired, but secondary defects formation increases
Solution Approach 1:
By concentrating the repair process only in locally identified defect areas rather than treating the entire component, the patent minimizes the zones subjected to thermal cycles and material deposition. This localized approach reduces the probability and extent of secondary defects such as unwanted welds, thermal distortion, or material contamination in non-defect areas.
Solution Approach 2:
The patent incorporates feedback by using scan data from the component substrate to dynamically control the deposition process. The system continuously references the scanned defect locations and adjusts deposition parameters and paths in real-time, ensuring precise material placement that avoids creating secondary defects and allows for process optimization based on actual defect characteristics.
3Loss of substance
If structured light scanning and sintering techniques are used, then material waste and secondary defects are reduced, but manufacturing process complexity increases
Solution Approach 1:
The patent applies universality by integrating multiple functions into a single repair system: the same apparatus performs scanning to identify defects, plans the repair path, deposits braze powder, and sinters the material. This multi-functional integration reduces the need for separate equipment for each operation, thereby managing overall device complexity while achieving precise, waste-reducing repairs.
Solution Approach 2:
The patent merges the scanning, deposition, and sintering operations into a coordinated sequence controlled by a single system. The scan data directly informs deposition parameters, and the sintering process is immediately followed based on deposition completion. This merging of operations streamlines the manufacturing process complexity by eliminating intermediate handling and setup steps between operations.
4Loss of substance
If structured light scanning and sintering techniques are used, then material waste and secondary defects are reduced, but repair time increases
Solution Approach 1:
The patent performs preliminary scanning and defect identification before the actual repair deposition begins. This pre-characterization of defects allows for optimized deposition paths and parameters to be calculated in advance, ensuring that during the repair phase, material is deposited efficiently only where needed, reducing overall repair time despite the added scanning step.
Solution Approach 2:
The patent maintains continuity of useful action by seamlessly transitioning from scanning to deposition to sintering without significant interruptions. The system continuously processes information from the scan and immediately applies it to control the deposition and sintering operations, ensuring that the repair process proceeds without idle time and minimizing total repair duration while maintaining precision and reducing waste.
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 reduces material waste and secondary defects by using structured light scanning and sintering techniques to precisely deposit and bond braze material, minimizing thermally induced stresses and distortion, while effectively repairing and restoring component integrity.
Implementation Method 1
a substrate is scanned using structured light to provide substrate scan data
Implementation Method 2
The braze powder is sintered together using a laser beam during the depositing of the braze powder
Implementation Method 3
The braze powder is sintered together during the depositing of the braze powder to provide the substrate with sintered braze material
Implementation Method 4
The furnace is configured to receive the substrate and melt the sintered braze material to facilitate diffusion bonding of the sintered braze material to the substrate
Data Source
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AI summary
A method is disclosed for providing a component (22). During this method, a substrate (44) is scanned using structured light to provide substrate scan data. The substrate scan data is compared to substrate reference data to provide additive manufacturing data. Braze powder (42) is deposited with the substrate (44) based on the additive manufacturing data. The braze powder (42) is sintered together during the depositing of the braze powder (42) to provide the substrate (44) with sintered braze material (64). The sintered braze material (64) is heated to melt the sintered braze material (64) and to diffusion bond the sintered braze material (64) to the substrate (44).