CT-Guided Adaptive Toolpaths for Precision Component Repair
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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 repair processes are not fully optimized for precision and material compatibility.
Innovation Solution
A method involving computed tomography scanning to generate additive manufacturing toolpaths, followed by machining toolpaths, using distinct powders for filling defects and restoring dimensions, with a laser-based additive manufacturing device to deposit and melt materials, and subsequent machining to achieve precise repair or manufacturing of components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If additive manufacturing is used to repair complex components, then material compatibility and precision are improved, but process complexity increases
Solution Approach 1:
The repair process is divided into distinct sequential stages: CT scanning to capture component geometry, additive manufacturing to deposit repair material, and machining to achieve final precision. This segmentation allows each stage to be optimized independently while maintaining overall process control and precision.
Solution Approach 2:
CT scanning is performed before the additive manufacturing process to capture the as-built geometry of the component. This preliminary action provides accurate spatial information that guides the subsequent repair operations, ensuring precision without requiring complex real-time adjustment systems.
2Measurement precision
If CT scanning is used to guide additive manufacturing, then repair accuracy is improved, but measurement and detection difficulty increases
Solution Approach 1:
The CT scanning process creates a digital copy of the component's internal and external geometry. This digital replica is then used to plan and guide the additive manufacturing process, eliminating the need for complex physical measurements during repair operations and maintaining high accuracy through digital modeling.
3Ease of repair
If multiple powders are used for defect filling and dimension restoration, then repair effectiveness is improved, but manufacturing complexity increases
Solution Approach 1:
Different powder materials are selectively deposited in different locations on the component based on the specific repair needs. First powder fills defects such as voids and cracks, while second powder restores dimensions. This local quality approach ensures each area receives the appropriate material properties without requiring a single complex multi-material system.
Solution Approach 2:
The repair material application is segmented into two distinct powder deposition processes: first powder for defect filling and second powder for dimension restoration. This segmentation simplifies the overall process by treating different repair functions separately rather than requiring a single complex multi-functional material 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 accurate repair and manufacturing of complex components by filling voids and restoring dimensions with high precision, reducing material costs and extending the life of components like those in gas turbine engines.
Implementation Method 1
scanning a component using computed tomography to provide scanned data
Implementation Method 2
scanning a component using computed tomography
Implementation Method 3
the additive manufacturing device melting the powder
Implementation Method 4
the additive manufacturing device melting the powder
Data Source
AI summary
A method of manufacturing a component includes scanning a component using computed tomography to provide scanned data. Additive manufacturing data is developed using the scanned data compared to reference data. Depositing powder using an additive manufacturing device based upon the additive manufacturing data to provide a first object the additive manufacturing device melting the powder. Determining predicted characteristics of the first object based upon the additive manufacturing data. The predicted characteristics of the first object are compared to the reference data to provide machining data. Machining the first object using the machining data then occurs. A system for manufacturing a component is also disclosed.