CT-Scanned Braze Filler Build-Up for Low-Waste Component Repair
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Solution Overview
Problem
Existing manufacturing processes for components 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 depositing braze powder onto a substrate, sintering it to form diffusion-bonded braze material, and then using computed tomography to scan and compare data to generate machining instructions, allowing for precise addition and removal of material to create a high-quality component, incorporating a system with a scanning device, additive manufacturing device, furnace, and machining device for adaptive manufacturing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional braze filler material or weld filler processes are used, then defects in a component can be repaired, but material waste increases and secondary defects are formed
Solution Approach 1:
The patent changes the physical and chemical parameters of the braze material by using powder form instead of traditional filler rods, and controls the deposition process through additive manufacturing parameters (layer thickness, deposition rate, temperature) to achieve precise material placement and reduce waste
Solution Approach 2:
The patent replaces traditional mechanical welding and brazing processes with an additive manufacturing system that deposits material layer-by-layer using controlled powder feed and energy source (laser or electron beam), eliminating the need for manual filler material handling and reducing secondary defects
2Reliability
If traditional braze filler material or weld filler processes are used, then defects in a component can be repaired, but formation of secondary (process related) defects increases
Solution Approach 1:
The patent replaces traditional mechanical welding and brazing processes with an additive manufacturing system that deposits material layer-by-layer using controlled powder feed and energy source (laser or electron beam), eliminating the need for manual filler material handling and reducing secondary defects
Solution Approach 2:
The patent applies material deposition only to the specific locations where defects are detected, rather than treating the entire component uniformly. The additive manufacturing system targets exact coordinates based on inspection data, ensuring local repair with minimal thermal affect and no secondary defects in unaffected areas
3Loss of substance
If additive manufacturing with CT scan data is used, then material waste is reduced and processing temperatures are minimized, but device complexity increases
Solution Approach 1:
The patent merges multiple manufacturing functions into an integrated system: CT scanning for inspection, additive manufacturing for deposition, and automated processing for fabrication. These functions are combined in a single workflow that uses digital data to coordinate all operations, reducing overall system complexity despite the advanced technologies involved
Solution Approach 2:
The patent implements a closed-loop feedback system where CT scan data from inspected components is fed into the additive manufacturing process to guide material deposition. The scan data provides real-time information about defect locations and component geometry, allowing the system to automatically adjust deposition parameters and target specific areas, minimizing material waste while maintaining simplicity through automation
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 enabling precise control over the deposition and bonding of braze material, resulting in improved component quality and reduced processing temperatures, which minimizes thermal stresses and distortion.
Implementation Method 1
a first object is scanned using computed tomography 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
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AI summary
A method is disclosed for providing a component. During this method, braze powder is deposited with a substrate. The braze powder is sintered together during the depositing of the braze powder to provide the substrate with sintered braze material. The sintered braze material is heated to melt the sintered braze material and to diffusion bond the sintered braze material to the substrate to provide braze filler material. A first object is scanned using computed tomography to provide first object scan data. The first object includes the substrate and the braze filler material diffusion bonded to the substrate. The first object scan data is compared to first object reference data to provide machining data. The first object is machined using the machining data to provide a second object.