Structured Light Machining After Additive Braze Diffusion Bonding
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing manufacturing processes for components, such as those in gas turbine engines, face challenges in reducing material waste and secondary defects, particularly in the application of braze filler material and weld filler, which can lead to inefficiencies and suboptimal results.
Innovation Solution
The method involves additive deposition of braze powder, sintering it to form diffusion bonds with the substrate, and using structured light scanning and machining to create a component that meets design specifications, thereby minimizing waste and defects through precise deposition and post-processing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of substance
If traditional braze filler material application processes are used, then the component can be repaired, but material waste and secondary defects increase
Solution Approach 1:
The patent applies parameter changes by transitioning from traditional braze filler material application to additive manufacturing processes. The additive manufacturing parameters (deposition rate, layer thickness, heating temperature) are precisely controlled to deposit material only where needed, reducing material waste while eliminating secondary defects through controlled sintering and diffusion bonding processes
Solution Approach 2:
The patent replaces traditional mechanical braze filler application methods with an additive manufacturing system that uses controlled material deposition and thermal processing. This substitution enables precise material placement and controlled bonding, reducing both material waste and secondary defects compared to conventional mechanical application methods
2Manufacturing precision
If additive manufacturing is used for braze powder deposition, then material precision is improved, but process complexity increases
Solution Approach 1:
The patent segments the additive manufacturing process into distinct operational phases: braze powder deposition, sintering, and diffusion bonding. Each phase is controlled by dedicated process parameters and can be independently optimized, reducing overall process complexity while maintaining high deposition precision through systematic breakdown of the manufacturing sequence
Solution Approach 2:
The patent introduces sintering as an intermediary process between powder deposition and final diffusion bonding. This intermediary step consolidates the powder layers into a coherent structure before final bonding, simplifying the overall process by creating distinct functional stages rather than attempting to achieve final density in a single deposition step
3Manufacturing precision
If structured light scanning and machining are used, then component accuracy is improved, but manufacturing time increases
Solution Approach 1:
The patent applies preliminary action by using structured light scanning immediately after additive manufacturing to capture the as-built geometry. This early scanning allows for precise machining operations to be planned and executed based on actual component dimensions, ensuring high accuracy while minimizing rework time by establishing the correct geometry from the outset
Solution Approach 2:
The patent implements feedback through the scanning and measurement process that compares actual component geometry against design specifications. This feedback loop enables real-time adjustment of machining parameters and validates that the additive manufacturing process achieved the desired precision, reducing iterative adjustments and overall manufacturing time
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 allowing for precise control over the deposition and bonding of braze filler material, resulting in a component that meets design specifications with reduced thermal stresses and distortion, and requires less post-processing.
Implementation Method 1
A first object is scanned using structured light to provide first object scan data
Implementation Method 2
The braze powder is sintered together during the depositing of the braze powder to provide the substrate with sintered braze material
Implementation Method 3
The sintered braze material is heated to melt the sintered braze material and to diffusion bond the sintered braze material to the substrate
Implementation Method 4
The sintered braze material is heated to melt the sintered braze material and to diffusion bond the sintered braze material to the substrate
Data Source
Figure 1
Figure 2
Figure 3
AI summary
A method is disclosed for providing a component (22). During this method, braze powder (44) is additively deposited with a substrate (46). The braze powder (44) is sintered together during the depositing of the braze powder (44) to provide the substrate (46) with sintered braze material (66). The sintered braze material (66) is heated to melt the sintered braze material (66) and to diffusion bond the sintered braze material (66) to the substrate (46) to provide braze filler material (88). A first object (90) is scanned using structured light to provide first object scan data. The first object (90) includes the substrate (46) and the braze filler material (88) diffusion bonded to the substrate (46). The first object scan data is compared to first object reference data to provide machining data. The first object (90) is machined using the machining data to provide a second object (92).