Component Overhaul Using CT-Guided Repair and Light-Scan Machining
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Solution Overview
Problem
Complex components, such as those in gas turbine engines, require efficient repair methods to address defects and wear without the high costs associated with replacement, as existing braze and weld filler application processes are not fully optimized.
Innovation Solution
A method involving CT scanning to generate additive manufacturing toolpaths, followed by structured light scanning to determine machining toolpaths, using distinct braze powders for filling voids and restoring dimensions, and subsequent machining to restore the component to its original state.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional braze and weld filler application processes are used to repair defects, then repair capability is provided, but manufacturing precision and dimensional accuracy are insufficient
Solution Approach 1:
The repair process is segmented into distinct phases: CT scanning for internal defect detection, additive manufacturing for precise material deposition, structured light scanning for surface verification, and selective machining for final dimensional accuracy. Each segment addresses specific requirements rather than attempting to achieve all goals in a single traditional repair operation.
Solution Approach 2:
The additive manufacturing step performs preliminary material deposition to restore dimensions before final machining. The structured light scan is performed preliminarily to verify the as-deposited geometry, allowing machining operations to be precisely planned and executed for achieving final dimensional accuracy.
2Reliability
If component replacement is chosen instead of repair, then reliability is maintained, but cost and resource waste increase
Solution Approach 1:
Instead of discarding the entire component when defects are detected, the method selectively repairs only the affected areas using additive manufacturing and machining. The majority of the component is recovered and reused, minimizing resource waste while maintaining overall reliability.
Solution Approach 2:
The component's local parameters (dimensions, geometry) are changed through additive manufacturing and machining to restore functionality. Rather than replacing the entire component, only the specific parameters affected by defects are modified to achieve the desired performance.
3Measurement precision
If CT scanning is used to obtain internal component data, then measurement precision is improved, but processing time and complexity increase
Solution Approach 1:
The method merges multiple scanning and manufacturing processes into an integrated workflow. CT scanning data is combined with structured light scanning data, and both are used together to guide additive manufacturing and machining operations, reducing overall processing time despite the complexity of individual steps.
Solution Approach 2:
The CT scan creates a digital copy of the component's internal geometry, which is then used to generate additive manufacturing toolpaths without requiring physical intervention during the scanning phase. This digital replica allows for offline processing and planning, reducing idle time during the physical repair process.
4Manufacturing precision
If additive manufacturing is used to deposit material, then manufacturing precision is improved, but device complexity increases
Solution Approach 1:
The additive manufacturing device serves multiple functions: it deposits material precisely based on CT scan data, creates the first repaired object, and its positioning system is subsequently used for structured light scanning. This multi-functionality reduces the need for separate specialized equipment for each operation.
Solution Approach 2:
The first object created by additive manufacturing serves as an intermediary between the digital design and the final repaired component. It allows verification of dimensional accuracy through structured light scanning before committing to final machining operations, reducing the risk of errors in the ultimate repair.
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 method allows for precise repair of complex components by effectively filling defects and restoring dimensions, reducing the need for replacement and improving the efficiency and accuracy of the repair process.
Implementation Method 1
scanning a component using computed tomography to provide first scanned data
Implementation Method 2
depositing material on the component using an additive manufacturing device based upon the additive manufacturing data to provide a first object
Implementation Method 3
scanning the first object using structural light scan to provide second scanned data
Data Source
AI summary
A method of overhaul of a component includes a) scanning a component using computed tomography to provide first scanned data, b) comparing the first 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) scanning the first object using structural light scan to provide second scanned data, and determining predicted characteristics of the first object based upon the second 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 the component is also disclosed.