CT-Guided Component Repair With Adaptive Additive Machining
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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 process data for additive manufacturing and machining, allowing for precise deposition and removal of material to form a component, utilizing an automated system that includes an additive manufacturing device and a machining tool to create or repair components based on reference data, thereby optimizing material usage and reducing waste.
Engineering Contradictions & Design Principles
Engineering 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
Solution Approach 1:
The patent applies local quality by using CT scan data to identify precise defect locations and applying material deposition only to those specific areas rather than treating the entire component. The machining operations are also localized to only the regions requiring correction, minimizing unnecessary material waste while effectively repairing defects.
Solution Approach 2:
The patent changes the parameters of the repair process by transitioning from traditional bulk material application to precision material deposition guided by CT scan data. The process parameters include controlled material deposition amounts, precise positioning based on scan data, and adaptive machining parameters that vary according to the specific defect characteristics and required correction levels.
2Reliability
If traditional braze material or weld filler processes are used to repair defects, then defects can be overhauled, but manufacturing costs increase
Solution Approach 1:
The patent implements feedback by using CT scan data to continuously monitor and guide the material deposition and machining processes. The scan data provides real-time information about defect locations, dimensions, and characteristics, allowing the system to adjust material application and machining parameters dynamically, thereby optimizing resource usage and reducing costs while maintaining repair quality.
Solution Approach 2:
The patent applies self-service by creating a closed-loop system where the component's own CT scan data guides its repair process. The scan data automatically identifies defects and generates the information needed for precise material deposition and machining, reducing the need for manual inspection and decision-making while ensuring accurate and cost-effective repairs.
3Manufacturing precision
If CT scan data is used to guide additive manufacturing and machining, then material deposition accuracy is improved, but process complexity increases
Solution Approach 1:
The patent applies universality by using a single CT scanning system to perform multiple functions: identifying defects, determining material deposition parameters, and guiding machining operations. This multi-functional approach consolidates what could be multiple separate inspection and control systems into one unified process, reducing overall system complexity while maintaining high precision material deposition.
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 the adaptive manufacturing of components with reduced waste and costs by ensuring accurate material deposition and removal, effectively restoring components to a like-new condition, tailored to specific defects and designs.
Implementation Method 1
scanning the substrate using computed tomography to provide substrate scan data
Implementation Method 2
The additive manufacturing may include laser metal deposition
Data Source
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.