CT-Guided Braze Repair With Diffusion Bonding and Precision Machining

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Solution Overview

Problem

Existing manufacturing processes for components using braze and weld filler materials result in material waste and secondary defects, necessitating a need for improved methods that reduce waste and defects while maintaining material integrity.

Innovation Solution

A method involving computed tomography scanning, additive manufacturing, and machining to deposit and diffusion bond braze powder to a substrate, followed by heating and machining to achieve precise repair and restoration of components.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Loss of substance

If traditional braze and weld filler material processes are used, then component repair can be achieved, but material waste and secondary defects increase

Engineering Contradiction:

Improvematerial wasteVSAvoidsecondary defects

Core Design Contradiction:

Loss of substanceVSReliability

Solution Approach 1:

The component is scanned using computed tomography before repair to identify exact defect locations and characteristics. This preliminary detection allows for precise targeting of filler material application, preventing waste and avoiding damage to sound areas.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The system applies filler material selectively only to identified defect regions rather than treating the entire component. This localized approach minimizes material waste and reduces the risk of introducing secondary defects in unaffected areas.

Inventive Principle:

Principle #3Local quality

2Strength

If high-temperature processing is used for braze and weld operations, then material bonding is achieved, but thermal stress and distortion increase

Engineering Contradiction:

Improvebonding strengthVSAvoidthermal stress

Core Design Contradiction:

StrengthVSStress or pressure

Solution Approach 1:

The system transitions from traditional high-temperature welding to lower-temperature alternative processes such as friction stir welding or ultrasonic welding. This parameter change maintains adequate bonding strength while significantly reducing thermal stress and distortion in the component.

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The invention replaces thermal bonding processes with mechanical bonding methods such as friction stir welding or ultrasonic welding. These mechanical processes achieve strong bonds without the high temperatures that cause thermal stress and distortion.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Manufacturing precision

If extensive post-processing machining is performed, then dimensional precision is improved, but production time and material loss increase

Engineering Contradiction:

Improvedimensional precisionVSAvoidpost-processing time

Core Design Contradiction:

Manufacturing precisionVSLoss of time

Solution Approach 1:

The filler material is applied in a controlled manner during the repair process itself, with real-time monitoring ensuring correct placement and dimensions. This self-correcting approach minimizes the need for subsequent machining operations to achieve dimensional precision.

Inventive Principle:

Principle #25Self-service

Solution Approach 2:

The system uses computed tomography scanning both before and after filler application to verify dimensional accuracy. This feedback loop allows for immediate correction during the repair process, eliminating the need for extensive post-processing machining.

Inventive Principle:

Principle #23Feedback

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

Reduces material waste and secondary defects by using low-temperature sintering and diffusion bonding, minimizing thermal stress and distortion, and requiring less post-processing, thus enhancing the quality and efficiency of component repair.

Implementation Method 1

a substrate is scanned using a computed tomography device to provide substrate scan data

Methodology Applied

Scientific EffectComputed tomography: Tomography

Implementation Method 2

Braze powder is deposited with a substrate. The braze powder is sintered together during the depositing of the braze powder to provide the substrate with sintered braze material

Methodology Applied

Scientific EffectLaser sintering: Selective Laser Sintering

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

Methodology Applied

Scientific EffectDiffusion bonding: Diffusion Welding

Data Source

PatentUS20250345856A1Adaptive manufacturing using CT scan data

Publication Date: 2025.11.13 PRATT & WHITNEY CANADA CORP

AI summary

A method is disclosed for providing a component. During this method, braze powder is deposited with a substrate. 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 to provide braze filler material. A first object is scanned using computed tomography to provide first object scan data. The first object includes the substrate and the braze filler material diffusion bonded to the substrate. 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.