Internal Defect Treatment Using Converging Beams in Parts

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Solution Overview

Problem

Internal defects such as porosity, lack of fusion, and cracks in manufactured parts, particularly in the aerospace industry, pose a significant challenge as they reduce fatigue resistance and lead to premature failure, necessitating a method to repair these defects without external material addition.

Innovation Solution

A method involving the detection and location of internal defects using non-destructive techniques, followed by simultaneous irradiation with multiple concurrent beams to achieve selective sintering or melting within a target volume, ensuring the energy deposited is below the sintering threshold for each beam but exceeds the transformation threshold when combined, allowing for defect repair without adding material.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If a single high-energy beam is used to treat the defect, then the transformation threshold is reached, but the material may be damaged or overheated

Engineering Contradiction:

Improvedefect treatment effectivenessVSAvoidmaterial damage from excessive energy

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The treatment process segments the energy delivery by using multiple beams (at least two) instead of a single beam. Each beam deposits energy below the sintering threshold individually, but their combined energy achieves the transformation threshold. This segmentation prevents localized overheating and material damage while still achieving effective defect treatment through cumulative energy deposition.

Inventive Principle:

Principle #1Segmentation

2Reliability

If multiple beams are used to irradiate the target volume, then the energy distribution is optimized, but the device complexity increases

Engineering Contradiction:

Improveenergy deposition controlVSAvoidnumber of beams required

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The invention merges multiple beam paths into a single target volume treatment. At least two beams are directed to converge on the same target volume containing the defect. The beams work synergistically, with their combined energy achieving the transformation threshold while each individual beam remains below the sintering threshold. This merging approach optimizes energy distribution and achieves reliable defect treatment.

Inventive Principle:

Principle #5Merging (Combining)

3Reliability

If the target volume is oversized relative to the defect, then the defect is fully treated, but more material is affected

Engineering Contradiction:

Improvedefect elimination completenessVSAvoidtreated material volume

Core Design Contradiction:

ReliabilityVSVolume of stationary object

Solution Approach 1:

The invention applies local quality by concentrating the combined beam energy precisely at the defect location within the target volume. The treatment is localized to where the defect exists, and the energy deposition is optimized to affect only the necessary material. The concurrent beams are positioned and focused to ensure that the treated volume is minimized while still fully encompassing and treating the defect, thereby maintaining local precision rather than applying uniform treatment to an oversized volume.

Inventive Principle:

Principle #3Local quality

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 effective repair of internal defects in three dimensions, homogenizing the material and eliminating defects like porosity by remelting the affected area, thereby extending the part's lifespan and preventing scrap, while maintaining the part's integrity.

Implementation Method 1

the energy deposited in the target volume by each beam is less than a sintering threshold energy of the material, and the sum of the energies deposited in the target volume by each of the beams is greater than or equal to a transformation threshold energy

Methodology Applied

Scientific EffectEnergy deposition: Heating

Implementation Method 2

the transformation threshold energy corresponding to the sintering threshold energy of the material, when selective sintering of the material in the target volume is desired

Methodology Applied

Scientific EffectSelective sintering: Sintering

Implementation Method 3

to the melting threshold energy of the material, when selective melting of the material in the target volume is desired

Methodology Applied

Scientific EffectSelective melting: Melting

Implementation Method 4

the material of the part is partially transparent to said at least two beams

Methodology Applied

Scientific EffectAbsorption of electromagnetic radiation: Absorption (EM radiation)

Data Source

PatentEP3956132B1Method for treating an internal defect in a part

Publication Date: 2023.03.15 SAFRAN AIRCRAFT ENGINES SAS

Figure 1a~1c
Figure 2a~2d

AI summary

Disclosed is a method for treating an internal defect (10) in a part (1) made of a material, said method involving: a) detecting and locating the internal defect (10) in the part; b) defining, inside the part, at least one target volume (4) which at least partially includes the defect; c) for each target volume (4), simultaneously irradiating the target volume by at least two beams (2) which converge in the target volume and are continuous, whereby a treated area is obtained. The energy applied to the target volume by each beam is less than a threshold energy for sintering the material, and the sum of the energies applied to the target volume by each of the beams is greater than or equal to a transformation threshold energy that corresponds to the threshold energy for sintering or melting the material; the material of the part is partially transparent to said beams.