Composite Repair Plugs to Protect Holes During Infiltration
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Solution Overview
Problem
Current methods for repairing composite components, such as ceramic matrix composite (CMC) gas turbine components, are costly and time-consuming due to the need for rework after infiltration, as infiltrant can damage features like holes and slots during the repair process.
Innovation Solution
A method involving the installation of plugs made from neutral materials within features of the composite component to block infiltrant flow, followed by infiltration to densify the repair region and subsequent removal of the plugs, preventing damage and reducing post-repair rework.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If infiltration is performed to densify the repair region, then the repair quality is improved, but the features (holes and slots) are damaged by infiltrant flow
Solution Approach 1:
The component is segmented into two functional zones: the repair region that requires infiltration for densification, and the features that must remain protected. Plugs are installed within the features to create a physical segmentation barrier, allowing infiltration to proceed in the repair region without contaminating the features.
Solution Approach 2:
Plugs serve as intermediary elements that mediate between the infiltrant and the features. These plugs are made from materials that are neutral to the infiltrant (do not bond chemically), allowing the infiltrant to flow freely into the repair region while being blocked from entering and damaging the features.
2Device complexity
If traditional repair methods are used without plugs, then the process is simpler, but post-repair rework is required due to feature damage
Solution Approach 1:
The plugs are installed before the infiltration process begins, performing a preliminary protective action. This preliminary placement of plugs prevents the need for post-repair rework by blocking infiltrant from damaging the features before the damage can occur.
Solution Approach 2:
The plugs are designed as temporary, disposable elements that serve their protective function during infiltration and are then removed. They are made from inexpensive, easily removable materials such as boron nitride or polytetrafluoroethylene, making their temporary use economically justified to prevent costly feature damage.
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 repairs composite components by preventing infiltrant flow into features, minimizing damage and rework, thus enhancing the efficiency and cost-effectiveness of the repair process.
Implementation Method 1
infiltrating the composite component with an infiltrant to densify a repair region of the composite component
Data Source
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AI summary
A method (100) for repairing composite components includes installing a plug (212) within a feature (202, 204) defined by a composite component (200), with the plug (212) being formed from one or more neutral materials. Furthermore, the method (100) includes infiltrating the composite component (200) with an infiltrant to densify a repair region (206) of the composite component (200), with the plug (212) blocking a flow of the infiltrant into the feature (202, 204). Moreover, after infiltrating the composite component (200), the method (100) includes removing the plug (212) from the feature (202, 204).