Brush Seal Alignment Tab Restoration for Faster Turbine Repair
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Solution Overview
Problem
Current methods for repairing brush seals in gas turbine engines are costly and time-consuming, requiring significant disassembly and replacement of parts during scheduled maintenance.
Innovation Solution
A method involving the removal, restoration, and reattachment of the alignment tab from a used brush seal assembly to a new one, where the alignment tab is machined to restore its dimensions and welded back onto the new assembly, allowing for efficient repair without full disassembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of repair
If current repair methods are used for brush seals, then the brush seal can be repaired, but significant disassembly and replacement of parts is required which increases time and cost
Solution Approach 1:
The brush seal assembly is divided into separable components: the alignment tab is detached from the brush seal assembly, allowing independent processing. This segmentation enables the alignment tab to be restored separately while the brush seal assembly can be replaced or maintained independently, reducing overall repair time and complexity.
Solution Approach 2:
Instead of discarding the entire brush seal assembly or requiring full replacement, the valuable alignment tab is recovered from the used assembly, restored to its original dimensions through machining or additive processes, and reused on a new or rebuilt assembly. This recovers the functional value of the alignment tab while eliminating the need for complete part replacement.
2Ease of repair
If current repair methods are used for brush seals, then the brush seal can be repaired, but significant disassembly and replacement of parts is required which increases cost
Solution Approach 1:
The alignment tab is recovered from the used brush seal assembly and restored rather than discarded. By machining or additively manufacturing material back onto the alignment tab, the original component is reused, avoiding the cost of purchasing new alignment tabs and reducing material waste.
Solution Approach 2:
The alignment tab's dimensions are restored through controlled material addition (additive manufacturing or machining) to return it to its original specifications. This parameter restoration allows the component to be reused without requiring expensive new parts, maintaining functional requirements while reducing material costs.
3Productivity
If the alignment tab is removed and restored, then the repair process is simplified, but additional machining and welding steps are required
Solution Approach 1:
The alignment tab is segmented from the brush seal assembly, allowing it to be processed independently. This separation enables parallel processing where the alignment tab can be restored while the brush seal assembly is handled separately, potentially improving overall repair throughput despite adding a detachment step.
Solution Approach 2:
The alignment tab is removed and restored in advance before final assembly. By performing the restoration work on the detached alignment tab beforehand, the actual assembly process is accelerated, and quality control can be applied to the restored tab independently, improving overall repair efficiency.
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 reduces the time and cost associated with repairing brush seals by allowing for the retention and repair of the alignment tab, simplifying the process and minimizing the need for complete disassembly and reassembly.
Implementation Method 1
attaching the restored alignment tab to a new brush seal assembly
Data Source
AI summary
A method of working a brush seal assembly for a turbine engine is disclosed and includes the steps of removing an alignment tab from a used brush seal assembly, restoring at least one dimension of the alignment tab to a desired condition and attaching the restored alignment tab to a new brush seal assembly.