CT-Guided Additive Repair and Machining for Defect Restoration

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Solution Overview

Problem

Existing manufacturing processes for components, such as those in gas turbine engines, face challenges in reducing material waste and manufacturing costs, particularly in repairing or overhauling defects using braze material or weld filler.

Innovation Solution

The method involves using computed tomography to scan and compare objects or substrates to generate machining data, allowing for precise additive manufacturing and machining to form or repair components, thereby reducing material waste and costs by selectively depositing and removing material based on detailed geometry and design specifications.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If traditional braze material or weld filler processes are used to repair defects, then defects can be overhauled, but material waste and manufacturing costs increase

Engineering Contradiction:

Improvedefect repair capabilityVSAvoidmaterial waste

Core Design Contradiction:

ReliabilityVSLoss of substance

Solution Approach 1:

The component is scanned using computed tomography before repair to identify and characterize defects in advance. This preliminary detection allows for precise planning of material deposition, ensuring that braze material or weld filler is applied only where needed rather than using conventional methods that require excess material application and removal.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

Traditional mechanical machining and material removal processes are replaced with additive manufacturing technology. The system deposits braze material or weld filler layer-by-layer precisely at defect locations identified by CT scanning, eliminating the need for conventional material removal and reducing overall material waste.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Reliability

If traditional braze material or weld filler processes are used to repair defects, then defects can be overhauled, but manufacturing costs increase

Engineering Contradiction:

Improvedefect repair capabilityVSAvoidmanufacturing cost

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

Conventional multi-step repair processes involving material removal, masking, and manual application are replaced with an integrated additive manufacturing system guided by CT scan data. This automation reduces labor costs and process complexity while maintaining high repair quality.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The system uses its own CT scanning capability to automatically detect and characterize defects, then uses this information to guide the additive manufacturing process. This self-directed approach eliminates the need for separate inspection and repair planning steps, reducing overall manufacturing costs.

Inventive Principle:

Principle #25Self-service

3Loss of substance

If additive manufacturing with CT scan guidance is used, then material waste is reduced, but process complexity increases

Engineering Contradiction:

Improvematerial waste reductionVSAvoidprocess complexity

Core Design Contradiction:

Loss of substanceVSDevice complexity

Solution Approach 1:

The CT scanning system and additive manufacturing system are integrated into a single workflow. The CT scan data is directly processed to generate toolpaths for material deposition, merging detection and manufacturing functions. This integration simplifies the overall process despite the advanced technology used, as the systems communicate and coordinate automatically.

Inventive Principle:

Principle #5Merging (Combining)

4Manufacturing precision

If additive manufacturing with CT scan guidance is used, then manufacturing precision is improved, but measurement and detection difficulty increases

Engineering Contradiction:

Improvedimensional accuracyVSAvoiddefect detection complexity

Core Design Contradiction:

Manufacturing precisionVSDifficulty of detecting and measuring

Solution Approach 1:

Physical contact measurement methods are replaced with non-contact computed tomography scanning. The CT system provides three-dimensional visualization of internal and external defects without touching the component, making defect detection easier while enabling precise guidance for subsequent additive manufacturing repairs.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

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 adaptive manufacturing that reduces waste and costs by tailoring material deposition and removal processes, ensuring components are restored to a like-new condition, improving efficiency and accuracy in repairing or forming components.

Implementation Method 1

The substrate is scanned using computed tomography to provide substrate scan data

Methodology Applied

Scientific EffectComputed tomography: Tomography

Implementation Method 2

Material is deposited with the substrate using an additive manufacturing device based on the additive manufacturing data

Methodology Applied

Scientific EffectAdditive manufacturing: 3D Printing

Data Source

PatentEP4335566A1Additively manufacturing using CT scan data

Publication Date: 2024.03.13 PRATT & WHITNEY CANADA CORP

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AI summary

A method is disclosed for providing a component. During this method, a first object is additive manufactured. The first object is scanned using computed tomography to provide first object scan data. The first object scan data is compared to first object reference data to provide machining data. The first object is machined using the machining data to provide a second object.