Airfoil Repair Joining Using Oversized Weld Attachment Sections
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Solution Overview
Problem
Current methods for repairing airfoil components in gas turbine engines are time-consuming, expensive, and have low yield rates, especially when dealing with damaged blades or blisks, as they often require replacing entire components rather than just the damaged portion, which can be costly and complex.
Innovation Solution
An airfoil repair system that includes a locally or wholly oversized airfoil repair component with a repair attachment section designed to align and secure to a cropped airfoil using an electrode assembly for precise positioning and welding, reducing the need for hand tools and enhancing the quality and speed of the repair process through features like inert gas shielding and adaptive current control.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional repair methods are used to repair airfoil components, then the repair process can handle complex damaged configurations, but the repair time increases and productivity decreases
Solution Approach 1:
The airfoil repair component is divided into a body portion and a separate attachment section that can be independently positioned and joined to the cropped airfoil, allowing for modular repair that reduces complexity and time
Solution Approach 2:
The attachment section is pre-configured with alignment features and positioning elements that enable direct attachment to the cropped airfoil without requiring extensive manual alignment or preparation work during the repair process
2Adaptability or versatility
If traditional repair methods are used to repair airfoil components, then the repair can be performed on various damaged configurations, but the cost increases and resource consumption increases
Solution Approach 1:
Instead of replacing entire airfoil components, the invention applies a localized attachment section only to the cropped portion of the airfoil where damage occurred, preserving the majority of the original component and reducing material waste
Solution Approach 2:
The invention recovers value from cropped airfoils that would otherwise be discarded by providing a repair component that can be attached to the remaining viable portion, thereby reducing material waste and resource consumption
3Ease of manufacture
If manual alignment and positioning methods are used, then the repair process can be performed with simple equipment, but the manufacturing precision decreases and alignment accuracy is poor
Solution Approach 1:
The attachment section incorporates pre-configured alignment features such as positioning protrusions or registration elements that automatically guide correct alignment with the cropped airfoil, eliminating the need for complex manual alignment procedures while maintaining high precision
Solution Approach 2:
The invention replaces manual mechanical alignment methods with built-in geometric alignment features and positioning mechanisms that provide automatic, precise alignment through the attachment section's design
4Strength
If complex joining procedures are used to attach repair components, then the joint strength can be ensured, but the device complexity increases and operation becomes difficult
Solution Approach 1:
The joining process is segmented into simplified steps facilitated by the attachment section's design, which may include pre-drilled holes, built-in fastening features, or localized welding zones that reduce the complexity of the joining procedure while maintaining joint strength
Solution Approach 2:
The attachment section incorporates self-aligning or self-securing features that reduce the need for complex external joining equipment or procedures, allowing for simpler operation while ensuring adequate joint strength through its design
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
The system improves the alignment and joining process, reducing repair time and costs while increasing the success rate of airfoil repairs by allowing for more accurate positioning and higher quality welds, even in complex configurations like blisks, and facilitates easier extraction of the repaired airfoil.
Implementation Method 1
passing current through the cropped airfoil electrode and the repair component electrode to join the airfoil repair component to the cropped airfoil
Implementation Method 2
US 2011/005075 relates to solid state resistance welding for airfoil repair
Data Source
Figure 1
Figure 2
Figure 3A~3B
AI summary
Repair components, systems, and methods are provided. For example, an airfoil repair component (200) for attaching to a cropped airfoil (140) comprises a body (205) and a repair attachment section (242) for attaching the airfoil repair component (200) to the cropped airfoil (140) at a cropped airfoil attachment section (142), the repair attachment section (242) being oversized with respect to the cropped airfoil attachment section (142) such that the repair attachment section (242) has a repair chord length (cr) longer than a cropped chord length (cc) of the cropped airfoil attachment section (142) and a repair width (wr) wider than a cropped width (wc) of the cropped airfoil attachment section (142). An airfoil repair system (300) comprises the airfoil repair component (200), a repair component electrode (304) for receipt of the airfoil repair component (200), and a tooling assembly (344) for positioning the airfoil repair component (200) with respect to the cropped airfoil (140). The repair component electrode (304) comprises a removable insert (330) surrounding at least a portion of the airfoil repair component (200).