Additive Manufacturing Control Blade for Tomographic Inspection Calibration
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Solution Overview
Problem
Existing methods for non-destructive testing of turbomachine blades with three-dimensional woven reinforcement composite materials are limited in detecting a wide range of defects due to the complexity of introducing resin clusters and the need for a fixed reference part, which only allows for limited characterization of defects.
Innovation Solution
A control blade is manufactured using additive manufacturing with housings of identical diameters to accommodate cylinders containing artificial or real defects, allowing for comprehensive defect characterization by tomography, where the cylinders have small-diameter holes surrounding a central blind hole to define material density, and resin plugs fill any voids to maintain position and minimize artifacts.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a fixed reference part with resin clusters is used for calibration, then the tomographic system can be calibrated, but the defect characterization is limited and the manufacturing is complex
Solution Approach 1:
The calibration system is divided into separate modular components: a blank part with standardized housings and removable defect cylinders. This segmentation allows the defect elements to be independently manufactured and then assembled into the calibration assembly, simplifying the overall manufacturing process while enabling comprehensive defect characterization.
Solution Approach 2:
The blank part with standardized housings serves multiple functions: it provides a consistent reference geometry, accommodates various defect types through interchangeable cylinders, and enables comprehensive calibration. The universal housing design allows the same blank to be used with different defect configurations.
2Adaptability or versatility
If a fixed reference part is used, then calibration can be performed, but it only allows characterization of very limited defects
Solution Approach 1:
The calibration system transitions from a static fixed reference part to a dynamic configurable assembly. The defect cylinders can be removed and replaced with different types, allowing the calibration system to adapt to various defect scenarios while maintaining a simple standardized housing structure.
Solution Approach 2:
The system enables changes in defect parameters (type, size, shape, location) by swapping different defect cylinders into the standardized housings. This parameter variability is achieved through a simple modular interface rather than complex integrated design.
3Measurement precision
If cylinders with artificial defects are inserted into housings, then complete defect characterization is achieved, but the assembly process becomes more complex
Solution Approach 1:
The calibration assembly is segmented into the blank with housings and separate defect cylinders. This segmentation enables independent manufacturing of each component with optimized processes, and simplifies assembly through standardized interfaces that require only fitting the cylinders into the housings.
Solution Approach 2:
Multiple identical housings and cylinders can be manufactured using the same standardized templates and processes. This copying approach simplifies manufacturing by repeating proven designs rather than creating unique components for each calibration assembly.
Data Source
Figure 1A~1B
Figure 2A~2C
Figure 3A~3D
AI summary
Method for manufacturing a control blade for calibrating a non-destructive tomographic inspection of actual blades that are similar in terms of shape and size. The method consists in producing a three-dimensional blank (10) from resin, creating housings (12, 14) in the thickness of this blank at predetermined locations, and introducing into each of the housings a cylinder (22, 24) comprising an artificial or actual defect in order to obtain the control blade.