CT-Scanned Component Repair With Braze Cladding and Machining
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Solution Overview
Problem
Complex components, such as those in gas turbine engines, require effective repair methods to extend their lifespan without the high costs associated with replacement, as existing braze and weld filler application processes are not fully optimized for precision and efficiency.
Innovation Solution
A method involving computed tomography scanning to generate additive manufacturing toolpaths, followed by material deposition using a direct laser braze cladding machine with distinct braze powders for voids and wear areas, and subsequent machining to restore the component to its original specifications.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional braze and weld filler application processes are used, then repair can be performed, but precision and efficiency are not optimized
Solution Approach 1:
The component is scanned using computed tomography before repair to create a three-dimensional digital model, allowing the repair path to be planned and optimized in advance. This preliminary digital modeling enables precise positioning of filler material application and machining operations, resolving the contradiction between precision and efficiency by preparing all parameters before actual repair begins
Solution Approach 2:
The computed tomography scan provides detailed internal structure data that feeds into the repair process planning. The digital model allows real-time adjustment of filler deposition parameters and machining paths based on actual defect locations and component geometry, enabling closed-loop control that simultaneously improves precision and efficiency
2Reliability
If complex components are replaced instead of repaired, then reliability is maintained, but operational costs increase
Solution Approach 1:
The invention changes the physical state and parameters of filler materials through controlled deposition processes. By precisely controlling material deposition parameters and using digital modeling to guide the process, the repair maintains component reliability while reducing material waste and operational costs compared to replacement
Solution Approach 2:
The component undergoes non-destructive computed tomography scanning to identify its own defects and structural characteristics. This self-diagnosis capability allows targeted repair only where needed, maintaining reliability while minimizing resource consumption and costs
3Manufacturing precision
If computed tomography scanning and additive manufacturing are used, then repair precision is improved, but process complexity increases
Solution Approach 1:
The computed tomography scan creates a digital copy or three-dimensional model of the component's internal structure. This digital replica allows virtual planning and simulation of repair operations before physical execution, simplifying the overall process by separating digital planning from physical execution while maintaining high precision
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 approach enables precise repair of complex components by filling defects and restoring dimensional accuracy, reducing material waste and operational costs while maintaining the component's performance.
Implementation Method 1
scanning a component using computed tomography to provide scanned data
Implementation Method 2
depositing material on the component using an additive manufacturing device based upon the additive manufacturing data
Data Source
AI summary
A method of overhaul of a component includes a) scanning a component using computed tomography to provide scanned data, b) comparing the scanned data to reference data to provide additive manufacturing data, c) depositing material on the component using an additive manufacturing device based upon the additive manufacturing data to provide a first object, d) determining predicted characteristics of the first object based upon the additive manufacturing data developed in step b) and the scanned data of step a), e) comparing the predicted characteristics of the first object to the reference data to provide machining data and f) machining the first object using the machining data. A system for overhauling a component is also disclosed.