Magnetic Compressor Blade Fixturing for Batch Repair Printing
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Solution Overview
Problem
Existing repair processes for compressor blades in gas turbine engines are labor-intensive, time-consuming, and costly, particularly due to the need for precise alignment and post-processing in additive manufacturing, which limits efficiency and scalability.
Innovation Solution
A tooling assembly for a powder bed additive manufacturing machine that includes a component fixture, mounting plate, and magnet assembly to securely position and orient multiple compressor blades uniformly, enabling precise repair segment printing directly onto the blades.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If traditional welding/cladding technique is used for blade repair, then repair materials can be bonded to blade tips, but the process requires tedious post-processing machining and polishing to achieve target geometry and surface finish
Solution Approach 1:
The patent replaces traditional mechanical welding/cladding processes with additive manufacturing technology. The additive manufacturing process deposits repair materials layer-by-layer directly onto blade tips according to digital models, eliminating the need for post-processing machining and polishing while achieving precise geometry and surface finish. This substitution of mechanical systems with digital manufacturing resolves the contradiction between bond strength and post-processing time.
2Manufacturing precision
If single blade repair process is used, then each blade can be repaired individually, but the process is very labor intensive and results in large overall labor costs
Solution Approach 1:
The patent merges multiple single-blade repair processes into a batch processing capability. The additive manufacturing system is configured to hold and repair multiple compressor blades simultaneously on a single build platform, allowing parallel processing of multiple components. This merging of operations maintains the precision of individual blade repair while dramatically increasing productivity by repairing multiple blades in one production cycle, thereby reducing overall labor costs.
3Measurement precision
If components are mounted at known and fixed spacing with uniform orientation, then vision system can more accurately determine blade tip coordinates and recoating process is improved, but the mounting process requires precise alignment and positioning
Solution Approach 1:
The patent applies preliminary action by pre-configuring the build platform with predetermined mounting locations and orientations for multiple blades. The additive manufacturing system is set up with pre-programmed positioning data that automatically guides the mounting process. This preliminary preparation of the build environment eliminates the need for complex real-time alignment operations, as components are placed at pre-determined coordinates with fixed spacing and uniform orientation, thereby improving measurement precision while reducing mounting complexity.
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
Facilitates efficient and accurate repair of compressor blades by ensuring consistent spacing and orientation, reducing labor costs and improving the speed of the repair process while maintaining high precision and quality.
Implementation Method 1
a magnet assembly operably coupling the mounting plate to the component fixture for securing the component fixture to the mounting plate in a desired orientation
Data Source
AI summary
A tooling assembly for mounting a plurality of components, such as compressor blades, in a powder bed additive manufacturing machine to facilitate a repair process is provided. The tooling assembly includes component fixtures configured for receiving each of the compressor blades, a mounting plate for receiving the component fixtures, and a magnet assembly operably coupling the component fixtures to the mounting plate in a desired position and orientation to facilitate an improved printing process.