CT-Guided Toolpaths for Precision Repair of Complex Components
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Solution Overview
Problem
Complex components, such as those in gas turbine engines, require efficient repair methods to reduce replacement costs, as existing additive manufacturing and machining techniques are not optimized for precision and material utilization.
Innovation Solution
A method involving CT scanning to generate additive manufacturing toolpaths and machining toolpaths, using CT scan data and reference data to deposit and remove materials precisely, allowing for the repair or creation of components with specific characteristics, including filling voids and forming claddings with different materials.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If additive manufacturing is used to repair components, then material can be deposited to fill defects, but achieving precise dimensional accuracy and structural integrity is difficult
Solution Approach 1:
The system performs preliminary CT scanning and defect characterization before additive manufacturing, allowing the toolpath to be pre-planned to deposit material precisely at defect locations. The machining operations are also pre-programmed based on predicted final dimensions, ensuring both dimensional accuracy and structural integrity are achieved through advance preparation rather than trial-and-error deposition.
Solution Approach 2:
The system uses CT scan data to obtain feedback on the actual component geometry and defect characteristics, comparing this against the digital model to adjust the additive manufacturing toolpath. This closed-loop feedback ensures material is deposited with precise dimensional control while maintaining structural integrity by targeting actual defect locations rather than relying solely on theoretical models.
2Manufacturing precision
If traditional machining techniques are used after additive manufacturing, then dimensional accuracy can be improved, but material is removed reducing efficiency
Solution Approach 1:
The system applies partial additive manufacturing by depositing material only at specific defect locations rather than rebuilding entire components, minimizing unnecessary material addition. The subsequent machining is also optimized to remove only the minimum amount of material needed to achieve dimensional accuracy, rather than extensive stock removal, thus reducing overall material waste while maintaining precision.
Solution Approach 2:
The system changes the approach from traditional subtractive machining to a hybrid process where additive manufacturing parameters (deposition rate, layer thickness, heat input) are optimized to achieve near-net-shape dimensions, reducing the amount of subsequent machining required. The machining parameters are also adjusted based on the actual material deposited, allowing for more efficient material removal with fewer passes and less total material loss.
3Measurement precision
If CT scanning is used to guide additive manufacturing, then deposition precision is improved, but process complexity increases
Solution Approach 1:
The system integrates multiple functions into a single automated workflow: CT scanning, defect detection, toolpath generation, and machining guidance are all performed by the same control system. This multi-functionality reduces the need for separate manual processes and interfaces, making the complex process more manageable despite the advanced capabilities required. The unified system handles both the additive manufacturing guidance and machining guidance from the same CT data foundation.
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
Enables accurate repair and manufacturing of complex components by ensuring precise deposition and removal of materials, improving the component's structural integrity and dimensional accuracy, thereby reducing costs and extending the lifespan of components.
Implementation Method 1
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
Implementation Method 2
scanning a component using computed tomography to provide scanned data
Data Source
Figure 1A~1C
Figure 2A
Figure 2B
AI summary
A method of manufacturing a component (20) 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 (40A, 40B) using an additive manufacturing device (24) based upon the additive manufacturing data to provide a first object, the additive manufacturing device (24) melting the powder (40). 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 (99) for manufacturing a component (20) is also disclosed.