Bridging Path Metal Composition for Hole Closure

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Solution Overview

Problem

Existing methods for closing multiple holes in metal articles, such as those in gas turbine components, are inefficient due to material deposition into internal channels, high costs, and time-intensive processes like standard welding or pre-sintered preform plugs.

Innovation Solution

Applying a metal composition along a bridging application path that passes over the holes, oscillating or non-oscillating, to close the holes without inserting plugs or brazing, using techniques like additive welding to reduce costs and increase efficiency.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If standard welding techniques are used to close holes, then holes can be closed, but material is deposited into internal channels and the process takes excessive time

Engineering Contradiction:

Improvehole closing speedVSAvoidmaterial deposition in internal channel

Core Design Contradiction:

ProductivityVSObject-affected harmful factors

Solution Approach 1:

The patent applies a localized bridging path that deposits metal composition only along the surface trajectory connecting hole edges, rather than filling holes vertically. This localized deposition approach closes holes by bridging surface openings without forcing material into internal channels, resolving the contradiction between closing efficiency and harmful material deposition.

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The invention transitions from traditional vertical hole-filling welding to a surface-level bridging approach. By applying metal composition along a bridging path that connects hole edges across the surface, the process operates in a different dimensional approach (surface trajectory rather than depth-oriented filling), achieving hole closure without internal channel contamination.

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

2Reliability

If pre-sintered preform plugs are inserted to close holes, then holes can be closed, but the process becomes costly and time-intensive due to precise machining requirements

Engineering Contradiction:

Improvehole closing effectivenessVSAvoidplug insertion and machining time

Core Design Contradiction:

ReliabilityVSLoss of time

Solution Approach 1:

The patent employs automated additive welding technology that self-adjusts and self-completes the hole closing process. The system automatically deposits metal composition along the bridging path, building up material to close holes without requiring manual plug insertion, precise machining of preforms, or complex assembly operations. This self-service approach eliminates time-intensive manual operations while maintaining reliable hole closure.

Inventive Principle:

Principle #25Self-service

Solution Approach 2:

The process prepares the surface by applying metal composition along the bridging path before complete hole closure occurs. This preliminary surface preparation ensures proper material distribution and flow patterns are established early in the process, enabling efficient hole closure without requiring subsequent precise machining or plug insertion operations.

Inventive Principle:

Principle #10Preliminary action

3Reliability

If pre-sintered preform plugs are used to close holes, then holes can be closed, but material costs increase due to expensive pre-sintered material

Engineering Contradiction:

Improvehole closing effectivenessVSAvoidcost of pre-sintered preform material

Core Design Contradiction:

ReliabilityVSLoss of substance

Solution Approach 1:

The patent replaces expensive pre-sintered preform material with standard metal composition fed through additive welding equipment. The metal composition is deposited directly in molten or semi-molten state and solidifies to close holes, eliminating the need for costly pre-sintered preforms. This substitution of materials significantly reduces substance costs while maintaining effective hole closure through the bridging deposition process.

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

Solution Approach 2:

The invention changes the physical state and application method of the closing material. Instead of using pre-sintered solid preforms that require expensive material and precise machining, the process uses metal composition in a depositable state (molten or semi-molten) applied through additive welding. This parameter change in material state and application method reduces material costs while achieving reliable hole closure.

Inventive Principle:

Principle #35Parameter changes

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 method effectively closes multiple holes quickly and cost-effectively, minimizing material deposition and crack formation, while maintaining process control and reducing the need for precise machining.

Implementation Method 1

using techniques like additive welding to reduce costs and increase efficiency

Methodology Applied

Scientific EffectAdditive welding: Welding

Data Source

PatentUS10610944B2Method for closing a plurality of holes in a metal article

Publication Date: 2020.04.07 GE INFRASTRUCTURE TECH LLC

AI summary

A method for closing a plurality of holes penetrating from a first surface of a metal article through a second surface of the metal article is disclosed including applying the metal composition to the first surface along a bridging application path. The bridging application path passes over the plurality of holes between a first edge of each of the plurality of holes and a second edge of each of the plurality of holes. Applying the metal composition along the bridging application path closes the plurality of holes.