Pre-configured Coating Patch Repair for Turbine Engine Components
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Solution Overview
Problem
Current methods for repairing coatings on aircraft turbofan gas turbine engine components, such as fan blades, are time-consuming, labor-intensive, and require disassembly of the engine due to the need for extensive removal and reapplication of coatings to address defects like chips and erosion.
Innovation Solution
A method involving the use of templates and pre-fabricated coating patches to create a coating aperture matching the patch configuration, allowing for efficient attachment and repair of the coating without disassembling the engine, using techniques like media blasting and adhesive application.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional coating removal and reapplication methods are used, then complete coating restoration is achieved, but repair time and labor intensity increase significantly
Solution Approach 1:
The repair process is segmented into targeted removal of only the defective coating portion rather than complete removal. The coating is segmented into defective and non-defective areas, allowing selective repair while preserving intact coating sections, thus reducing repair time while maintaining restoration quality.
Solution Approach 2:
Pre-configured coating patches are prepared in advance with matching geometry and material properties. The patches are pre-fabricated to exact specifications before the repair process, eliminating on-site preparation time and enabling rapid application to the prepared aperture, thereby reducing overall repair time while ensuring restoration quality.
2Reliability
If complete coating removal is performed, then defect elimination is ensured, but equipment and labor requirements increase
Solution Approach 1:
The repair method applies local quality by treating only the defective portion of the coating with targeted removal techniques. The aperture is precisely configured to match the defect boundaries, allowing removal of defective material while preserving surrounding intact coating, thus eliminating defects without requiring complete coating removal and associated heavy equipment.
Solution Approach 2:
Pre-configured coating patches are created as exact copies or matches to the original coating specifications, geometry, and material properties. These patches replicate the original coating characteristics, ensuring defect elimination through replacement while using simpler application equipment compared to complete coating removal and reapplication systems.
3Reliability
If traditional repair methods are used, then coating defects are eliminated, but aircraft downtime increases
Solution Approach 1:
The repair process segments the work into focused, localized steps rather than requiring complete engine disassembly. Only the specific defective coating area is targeted for removal and replacement, allowing the rest of the engine to remain assembled and operational, thus eliminating defects while minimizing aircraft downtime and maintaining productivity.
Solution Approach 2:
Coating patches are pre-configured and prepared in advance with exact geometric and material specifications. This preliminary preparation eliminates on-site fabrication time and enables rapid application to the prepared aperture, ensuring complete defect elimination while significantly reducing the time the aircraft is out of service, thereby maintaining high operational availability.
4Manufacturing precision
If precise coating aperture configuration is achieved, then patch fit and repair quality improve, but manufacturing complexity increases
Solution Approach 1:
The pre-configured coating patches are designed with universal applicability through standardized fabrication processes that can produce multiple patches with consistent precision. The patches incorporate universal geometric configurations that can be adapted to various defect types while maintaining manufacturing precision, reducing the need for custom complex tooling for each repair scenario.
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 downtime by enabling on-wing repair of turbine engine components, maintaining aircraft operation while allowing for precise and efficient restoration of the coating without the need for extensive disassembly, thus improving repair efficiency and reducing labor costs.
Implementation Method 1
attaching the first coating patch to the component body
Implementation Method 2
removing a portion of the coating from the component body thereby forming a coating aperture
Data Source
AI summary
A method is provided for repairing a component of an item of rotational equipment, where the component includes a coating and a component body, and where the coating is on the component body and includes a defect. The method includes steps of: (a) removing a portion of the coating from the component body thereby forming a coating aperture, the removed portion of the coating including the defect, and the portion of the coating is removed such that the coating aperture has a coating aperture configuration which substantially matches a first patch configuration of a first coating patch; (b) preparing the component at the coating aperture to receive the first coating patch, (c) disposing the first coating patch within the coating aperture; and (d) attaching the first coating patch to the component body.