Sacrificial Surface for DED Repair Across Through-Hole Aerospace Regions
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Solution Overview
Problem
Current repair techniques for aerospace components, such as gas turbine engine components, are inadequate for components lacking sufficient substrate material or suitable substrate material, especially for through holes or separated features, limiting the applicability of directed energy deposition (DED) techniques.
Innovation Solution
The use of a sacrificial backing feature attached to the aerospace component provides a platform for DED repair, allowing the deposition of layers with controlled residual stress state and microstructure, using DED process parameters like powder feed rate, energy intensity, traversal rate, and auxiliary heating/cooling to extend the repair across sections and through holes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If traditional repair techniques are used on aerospace components, then components with sufficient substrate material can be repaired, but components lacking sufficient substrate material or having through holes cannot be repaired
Solution Approach 1:
A sacrificial backing feature is introduced as an intermediary element attached to the rear surface of the aerospace component. This backing feature provides a platform for DED material deposition in regions where the component itself cannot support direct deposition, such as through holes or areas with insufficient substrate thickness. The backing feature enables the repair process while being removed after repair completion.
Solution Approach 2:
The repair process is segmented into distinct phases: attachment of sacrificial backing feature, DED material deposition on the backing feature, removal of the backing feature, and final repair completion. This segmentation allows each phase to be optimized independently, enabling repair of component geometries that would otherwise be incompatible with traditional DED methods.
2Ease of repair
If directed energy deposition is used to repair aerospace components, then repair capability is improved, but the method is limited to components with sufficient substrate material
Solution Approach 1:
The sacrificial backing feature is attached to the component surface before initiating the DED repair process. This preliminary action prepares the surface to receive DED material deposition in regions where the component geometry would otherwise prevent successful repair, such as through holes or thin-walled areas.
Solution Approach 2:
The sacrificial backing feature serves as a temporary intermediary substrate that enables DED deposition in geometrically challenging regions. It provides a stable platform for material accumulation that is subsequently removed, leaving only the repaired component without traces of the backing feature.
3Ease of operation
If sacrificial backing material is used to enable DED repair, then repair accessibility is improved, but additional material removal step is required
Solution Approach 1:
The sacrificial backing feature is completely removed after serving its purpose during the DED repair process. This extraction eliminates the temporary support structure, leaving only the repaired component. The removal step is necessary but manageable through various methods including machining, grinding, or chemical dissolution depending on the backing feature material.
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 in components previously unsuitable for such methods, providing controlled mechanical and functional properties, extending the life of the repaired aerospace parts by expanding the number of available repair methods.
Implementation Method 1
depositing, using the DED energy/powder head, a first layer of DED powder material in the repair region; melting and consolidating, using energy from the DED energy/powder head, the first layer of DED powder material to form a first repair layer
Implementation Method 2
A sacrificial backing material, which serves as a platform for deposition of repair layers during a repair procedure, is attached to the aerospace part
Data Source
AI summary
A method of repairing an aerospace part including inspecting the aerospace part, made from a base material, to identify a worn or defective repair region that requires repair. A sacrificial backing material, which serves as a platform for deposition of repair layers during a repair procedure, is attached to the aerospace part. A repair procedure is performed on the repair region using a directed energy deposition (DED) energy/powder head after which the sacrificial backing material is removed from the aerospace part and the aerospace part is returned to service. The repair procedure includes depositing, using the DED energy/powder head, a first layer of DED powder material in the repair region; melting and consolidating, using energy from the DED energy/powder head, the first layer of DED powder material to form a first repair layer having a pre-determined residual stress state and/or microstructure; and repeating the depositing and melting and consolidating steps to create a desired plurality of repair layers.