Composite Blade Metal Edge Repair by Local Patch Rebonding
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Solution Overview
Problem
Conventional methods for repairing composite blades, particularly those used in gas turbine engines, often require the replacement of entire metallic edges due to localized damage, which is economically and time-wise inefficient, and involves complex debonding processes.
Innovation Solution
A method for repairing composite blades by locally removing and replacing only the damaged metal work components, including a bullet and wing portions, using a combination of cutting, heating, and manual debonding techniques to minimize material waste and tool complexity, allowing for reconditioning and rebonding with adhesive layers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the entire metallic material is replaced due to localized damage, then the blade reliability is improved, but the repair cost and time increase significantly
Solution Approach 1:
The metallic material is divided into a damaged portion and an undamaged portion. Only the damaged segment is removed and replaced, while the undamaged segment is retained. This segmentation allows localized repair instead of complete replacement, significantly reducing repair time and cost while maintaining blade reliability.
Solution Approach 2:
The repair process applies local quality by treating only the damaged area with specialized debonding and replacement procedures, while the undamaged areas remain untouched. This localized approach focuses resources where needed, improving efficiency without compromising overall blade reliability.
2Reliability
If the entire metallic material is replaced due to localized damage, then the blade reliability is improved, but the material cost increases
Solution Approach 1:
The metallic material is segmented into damaged and undamaged portions. By removing only the damaged segment and retaining the undamaged segment, material waste is minimized. This approach preserves valuable metallic material while ensuring blade reliability through targeted replacement of only the compromised portion.
Solution Approach 2:
The undamaged metallic material is recovered and reused in the repaired blade, while only the damaged portion is discarded and replaced. This recovery and reuse of sound material significantly reduces material costs while maintaining the required blade reliability.
3Reliability
If sophisticated tools and complex debonding processes are used for metallic material replacement, then the repair completeness is improved, but the device complexity increases
Solution Approach 1:
Instead of applying complex debonding processes to the entire metallic material, the method applies partial action by focusing debonding efforts only on the damaged portion. This reduces the complexity of tools and processes required while achieving complete repair of the damaged area, as the undamaged portion does not require debonding.
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 enables localized repair of composite blades, reducing costs and time by salvaging undamaged materials, eliminating the need for sophisticated tools, and preserving protective coatings, thus optimizing the repair process.
Implementation Method 1
an adhesive layer bonding the metal work to the composite part
Implementation Method 2
heating the composite blade to a temperature between 50°C and 100°C
Implementation Method 3
heating the composite blade to a temperature between 50°C and 100°C for softening of an adhesive layer
Data Source
AI summary
A method of repairing a composite blade. The composite blade includes a metal work bonded to a composite part through an adhesive layer. The method includes determining a locally damaged portion of the metal work, and removing a bullet portion corresponding to the locally damaged portion. The method further includes detaching, debonding, and removing a first wing portion from the composite part to obtain a first exposed surface portion. The method further includes detaching, debonding, and removing a second wing portion from the composite part to obtain a second exposed surface portion. The method further includes reconditioning the first and second exposed surface portions to obtain first and second reconditioned surface portions, respectively, and applying first and second adhesive layers to the first and second reconditioned surface portions respectively. The method further includes bonding a metal work patch to the first and second adhesive layers.