Composite Repair Plugging for Infiltrant-Protected Features

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Solution Overview

Problem

Current methods for repairing composite components, such as ceramic matrix composite (CMC) gas turbine components, are inefficient and costly due to the need for extensive rework after infiltration, as infiltrant can damage features like holes and slots, requiring expensive and time-consuming repairs.

Innovation Solution

A method involving the installation of plugs made from neutral materials within features of the composite component to block infiltrant flow during the infiltration process, followed by removal of the plugs, allowing for effective densification of the repair region without damaging the component's features.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If infiltration is performed to densify the repair region, then the repair quality is improved, but the infiltrant damages the features (holes and slots) requiring extensive rework

Engineering Contradiction:

Improverepair qualityVSAvoidinfiltrant damage to features

Core Design Contradiction:

Manufacturing precisionVSObject-affected harmful factors

Solution Approach 1:

The component is segmented into two distinct zones: the repair region that requires infiltration and the features (holes and slots) that must be protected. By physically separating these zones using plugs, the infiltration process can proceed without damaging the features, thus resolving the contradiction between achieving high repair quality and preventing infiltrant damage.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Plugs made from neutral materials serve as intermediary elements between the infiltrant and the features. These plugs block the infiltrant from entering the features while allowing the infiltration process to proceed in the repair region. The neutral material composition ensures the plugs do not react with the infiltrant, enabling effective protection without compromising the repair quality.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Reliability

If plugs are installed to protect features during infiltration, then feature integrity is maintained, but the device complexity increases

Engineering Contradiction:

Improvefeature integrityVSAvoidrepair process complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The plugs are installed in advance of the infiltration process, before the infiltrant is applied. This preliminary protective action ensures that the features are shielded from potential damage throughout the entire infiltration operation. By preparing the protection measures beforehand, the actual infiltration can proceed smoothly without interruptions or complications, thus maintaining feature integrity while managing process complexity.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The plugs serve as temporary, disposable elements that are installed for the duration of the infiltration process and then removed afterward. These plugs are not intended to remain in the component permanently but rather to fulfill their protective function temporarily and then be discarded. This approach maintains feature integrity during the critical infiltration phase while avoiding permanent additions to the component complexity.

Inventive Principle:

Principle #34Discarding and recovering

3Ease of manufacture

If traditional repair methods are used without plugs, then the process is simpler, but extensive rework is required after infiltration

Engineering Contradiction:

Improverepair process simplicityVSAvoidpost-repair rework time

Core Design Contradiction:

Ease of manufactureVSLoss of time

Solution Approach 1:

The plugs provide beforehand protection against the harmful effects of infiltrant exposure to features. By cushioning or shielding the features from potential damage before the infiltration process begins, the need for time-consuming rework after infiltration is eliminated. This prior protective measure ensures that when the infiltration is complete, the features remain intact and no additional repair or restoration work is required, thus resolving the contradiction between process simplicity and time efficiency.

Inventive Principle:

Principle #11Beforehand cushioning (Prior cushioning)

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 efficient and cost-effective repair of composite components by preventing infiltrant entry into features, reducing post-repair rework and maintaining the integrity of the component's structure, thereby extending the lifespan of CMC components.

Implementation Method 1

the plug blocking a flow of the infiltrant into the feature

Methodology Applied

Scientific EffectPhysical barrier blocking:

Implementation Method 2

infiltrating the composite component with an infiltrant to densify a repair region of the composite component

Methodology Applied

Scientific EffectInfiltration: Capillary Action

Data Source

PatentUS11548102B2Method for repairing composite components using a plug

Publication Date: 2023.01.10 GENERAL ELECTRIC CO

AI summary

A method for repairing composite components includes installing a plug within a feature defined by a composite component, with the plug being formed from one or more neutral materials. Furthermore, the method includes infiltrating the composite component with an infiltrant to densify a repair region of the composite component, with the plug blocking a flow of the infiltrant into the feature. Moreover, after infiltrating the composite component, the method includes removing the plug from the feature.