Aerospace Part Repair by Removing Features for DED Access
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Solution Overview
Problem
Existing repair techniques for aerospace components, such as gas turbine engine components, are limited by the inability to access repair sites due to intervening features that block line-of-sight, preventing the use of directed energy deposition (DED) techniques.
Innovation Solution
The method involves removing intervening features to create line-of-sight for DED laser/powder heads, repairing the exposed site using DED techniques, and reattaching a replacement feature using DED or additive manufacturing (AM) methods.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If DED repair techniques are used on aerospace components, then repair capability and component reliability are improved, but access to repair sites is blocked by intervening features preventing line-of-sight
Solution Approach 1:
The aerospace component is divided into segments by removing intervening features (such as ribs or protrusions) that block access to the repair site. This segmentation allows the DED laser/powder head to access previously inaccessible areas while maintaining the structural integrity of the remaining components through careful selection of what to remove versus what to preserve.
Solution Approach 2:
Intervening features that block line-of-sight to the repair region are selectively removed or extracted from the component. This extraction creates the necessary line-of-sight for DED repair operations while minimizing removal to only what is absolutely necessary for access, preserving as much of the original component structure as possible.
2Ease of operation
If intervening features are removed to enable DED access, then line-of-sight access to repair region is improved, but component structure is modified requiring replacement features
Solution Approach 1:
Replacement intervening features are designed and prepared in advance using additive manufacturing techniques before the actual repair operation. This preliminary action allows for precise planning of the restoration process and ensures that replacement features are ready for immediate installation after the DED repair is completed, minimizing overall repair time.
Solution Approach 2:
The material properties, geometric parameters, and structural characteristics of replacement intervening features are optimized through additive manufacturing parameters. By controlling deposition parameters, layer thickness, and thermal cycles, the replacement features achieve mechanical properties matching or exceeding the original component, ensuring structural integrity after restoration.
3Strength
If replacement intervening features are added to restore component structure, then component integrity is improved, but repair process complexity increases
Solution Approach 1:
The repair process merges multiple operations into an integrated workflow: inspection, intervening feature removal, DED repair of the target region, and additive manufacturing of replacement features. This merging allows for coordinated planning and execution, reducing the need for separate tooling and processes that would otherwise increase complexity.
Solution Approach 2:
The DED system performs multiple functions: it repairs the target region, removes intervening features (through laser ablation capability), and can manufacture replacement intervening features. This multi-functionality consolidates what would otherwise require multiple different equipment systems into a single versatile platform, managing complexity through integration.
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 DED repairs on previously inaccessible components, expanding the range of repair methods and ensuring aerospace parts can be returned to service.
Implementation Method 1
directed energy deposition (DED) techniques requires line-of-site access to a site or feature in need of repair but line-of-site is not always available due to intervening features that block the line-of-site
Implementation Method 2
providing DED material powder and laser energy, shown collectively as item 20 in FIG. 2, from the DED laser/powder head 18 is to the repair region 24 to accomplish the desired repair
Implementation Method 3
providing DED material powder and laser energy, shown collectively as item 20 in FIG. 2, from the DED laser/powder head 18 is to the repair region 24 to accomplish the desired repair
Data Source
AI summary
An aerospace part, which is made from a base material, repairing using directed energy deposition (DED) techniques. The aerospace part is inspected to identify a worn or defective repair region on a repair feature that requires repair. An intervening feature that blocks line-of-sight from a DED laser/powder head to the repair region on the repair feature is removed such that after removal of the intervening feature there is line-of-sight from the DED laser/powder head to the repair region on the repair feature. a repair procedure is performed on the repair region of the repair feature using the DED laser/powder head. A replacement intervening feature is obtained and attached to the aerospace part to complete a desired repair. The aerospace part is returned to service after completion of the desired repair.