High-Pressure Compressor Vane Debris Extraction
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Solution Overview
Problem
Current methods for removing foreign bodies from high-pressure distributor blades in turbomachines require stripping and reapplying thermal barriers, leading to dimensional changes, residue risks, and increased costs due to the need for repeated thermal barrier installation.
Innovation Solution
A method involving cutting and replacing only the closing plate of the blade, allowing for foreign body extraction without removing the thermal barrier, followed by endoscopic inspection and re-brazing a new closing plate directly onto the blade coated with the thermal barrier.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the thermal barrier is stripped and reappplied to remove a foreign body, then the foreign body can be removed from the cavity, but the blade dimensions change and the process becomes more complex and expensive
Solution Approach 1:
The invention extracts only the closing plate from the blade cavity, separating it from the thermal barrier coating. This allows the foreign body to be removed while preserving the thermal barrier integrity, avoiding the need to strip and reapply the entire thermal barrier system.
Solution Approach 2:
The blade cavity is segmented into two independent parts: the closing plate that can be removed and replaced, and the thermal barrier coating that remains intact on the blade. This segmentation allows selective replacement of only the problematic closing plate without affecting the thermal barrier.
2Reliability
If the thermal barrier is stripped and reappplied, then foreign bodies can be removed, but dimensional changes occur and residue risks increase
Solution Approach 1:
The closing plate is extracted as a separate removable component, allowing foreign bodies to be removed without affecting the blade's dimensional stability. The thermal barrier coating remains intact, preserving the original blade dimensions.
Solution Approach 2:
The solution applies local quality by affecting only the specific area where the foreign body is located (the closing plate) while leaving the rest of the blade and its thermal barrier coating unchanged, thus maintaining manufacturing precision.
3Reliability
If the thermal barrier is stripped and reappplied, then foreign bodies can be removed, but costs increase due to repeated installation
Solution Approach 1:
The closing plate is discarded when contaminated with foreign bodies and replaced with a new one, while the thermal barrier coating is recovered and retained on the blade. This avoids the expensive process of stripping and reapplying the entire thermal barrier system.
Solution Approach 2:
By extracting and replacing only the closing plate rather than the entire thermal barrier system, the manufacturing cost is significantly reduced while still achieving reliable foreign body removal.
4Stability of the object's composition
If the closing plate is replaced without removing the thermal barrier, then the thermal barrier integrity is maintained, but the foreign body may remain trapped
Solution Approach 1:
The closing plate is completely extracted from the cavity, creating an open space where foreign bodies can be easily removed. This extraction ensures that no foreign bodies remain trapped between the closing plate and the blade, while the thermal barrier integrity is maintained.
Solution Approach 2:
The closing plate is removed as a preliminary action before final inspection, allowing foreign bodies to be extracted from the cavity. This preliminary extraction ensures complete foreign body removal while preserving the thermal barrier for subsequent inspection and operation.
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
Enables the removal of foreign bodies without altering the blade's dimensions or thermal barrier integrity, reducing costs and compliance risks, while maintaining the blade's performance and adhering to technical specifications.
Implementation Method 1
brazing the second closing plate directly on the distributor with the blades coated with the thermal barrier
Implementation Method 2
The outer layer, that is to say the most exposed to hot gases, of the thermal barrier is generally a ceramic layer. The main function of this ceramic layer is thermal insulation.
Data Source
Figure 1~2
Figure 3~4
Figure 5~6B
AI summary
The invention concerns a method for extracting at least one foreign body lodged within a blade (110) of a high-pressure distributor of a turbojet engine, the high-pressure distributor comprising hollow fixed blades (110) between two annular shrouds forming a gas flow path, each blade being coated with a thermal barrier and provided with at least one recess at least partially obstructed by a first soldered closing plate (140), comprising the following operations: - cutting off (310) the first closing plate, - extracting (320) the foreign body from the recess, - carrying out an endoscopic inspection (330) of an internal space of the recess in order to verify that no foreign body remains, - positioning (340) a second closing plate on the recess, and - soldering (350) the second closing plate directly onto the distributor with the blades coated with the thermal barrier.