CT-Driven Braze Deposition and Diffusion Bonding for Defect Repair
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing manufacturing processes for components face challenges in reducing material waste and minimizing the formation of secondary defects during the application of braze material or weld filler.
Innovation Solution
The method involves scanning a substrate using computed tomography to generate additive manufacturing data, which guides the deposition and sintering of braze powder to create sintered braze material. This material is then heated to melt and diffusion bond with the substrate, using a system comprising a scanning device, a controller, an additive manufacturing device, and a furnace.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of substance
If traditional braze material application processes are used, then material waste increases and secondary defects form, but the process is simpler and more established
Solution Approach 1:
The substrate is scanned using computed tomography before the braze material application process to identify defects and plan the repair strategy in advance. This preliminary inspection allows the additive manufacturing device to precisely target only the areas requiring repair, avoiding unnecessary material application and reducing material waste while minimizing secondary defects.
Solution Approach 2:
The system uses computed tomography scanning to obtain real-time or near-real-time data about the substrate condition and compares it with reference data to generate additive manufacturing data. This feedback loop enables precise control of the braze material deposition, ensuring material is applied only where needed and in the correct amounts, thereby reducing material waste and preventing secondary defects from improper application.
2Manufacturing precision
If additive manufacturing with CT scan data is used, then manufacturing precision improves, but device complexity increases
Solution Approach 1:
The additive manufacturing device integrates multiple functions into a single system: it receives and processes computed tomography scan data, compares it with reference data, generates additive manufacturing data, and executes precise braze material deposition. This multi-functionality reduces the need for separate inspection and repair systems, managing complexity while achieving high manufacturing precision through unified control.
Solution Approach 2:
The system transforms the substrate inspection data from computed tomography scans into additive manufacturing data by comparing with reference data and adjusting deposition parameters accordingly. This parameter transformation enables precise control of braze material application, achieving high manufacturing precision by dynamically adjusting deposition parameters based on actual substrate conditions rather than using fixed parameters.
3Reliability
If multiple braze powders are deposited, then repair quality improves for different defect types, but process time increases
Solution Approach 1:
The system applies different braze powders to different regions of the substrate based on the specific defect types and locations identified through computed tomography scanning. Each defect area receives the most appropriate braze material for its specific condition, improving repair quality and reliability. The additive manufacturing device efficiently manages multiple powder deposits by planning the deposition sequence to minimize process time while ensuring each area receives the correct material.
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 reduces material waste and decreases the formation of secondary defects by precisely depositing and bonding braze material to the substrate, thereby enhancing the quality and efficiency of the manufacturing process.
Implementation Method 1
a substrate is scanned using computed tomography to provide substrate scan data
Implementation Method 2
The braze powder is sintered together using a laser beam during the depositing of the braze powder
Implementation Method 3
The sintered braze material is heated to melt the sintered braze material and to diffusion bond the sintered braze material to the substrate
Implementation Method 4
heated to melt the sintered braze material
Data Source
AI summary
A method is disclosed for providing a component. During this method, a substrate is scanned using computed tomography to provide substrate scan data. The substrate scan data is compared to substrate reference data to provide additive manufacturing data. Braze powder is deposited with the substrate based on the additive manufacturing data. The braze powder is sintered together during the depositing of the braze powder to provide the substrate with sintered braze material. The sintered braze material is heated to melt the sintered braze material and to diffusion bond the sintered braze material to the substrate.