Directed Energy Deposition for Gas Turbine Repair
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Solution Overview
Problem
High temperature components, such as those in gas turbine engines, face issues like cracking and wear due to extreme environments, and existing repair techniques struggle to maintain the original microstructure and mechanical properties during modification or repair.
Innovation Solution
A directed energy deposition technique is employed, where a computing device controls an energy source to form an advancing molten pool and a material delivery device to deposit a layer with a controlled target height, affecting the resultant microstructure and reducing flaws like cracks and pores.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of repair
If welding, brazing, cladding, or other conventional techniques are used to modify or repair high temperature components, then the components can be restored or modified, but the original microstructure and mechanical properties are compromised
Solution Approach 1:
The patent replaces conventional mechanical repair techniques (welding, brazing, cladding) with a directed energy deposition process that uses precise thermal control to deposit material. This substitution of the repair mechanism allows for better preservation of the base metal's microstructure by limiting thermal affect zone and controlling heat input parameters, thereby resolving the contradiction between ease of repair and microstructure stability
Solution Approach 2:
The patent employs precise control of process parameters including energy beam power, travel speed, and deposition rate to maintain the base metal's microstructure during repair. By optimizing these parameters, the process achieves effective component restoration while minimizing thermal damage and preserving the original material properties, thus resolving the contradiction between repair effectiveness and microstructure preservation
2Productivity
If high energy input is used to deposit material quickly, then productivity increases, but the resultant microstructure contains more flaws such as cracks and pores
Solution Approach 1:
The patent employs dynamic control of the energy beam parameters and deposition rate during the directed energy deposition process. The system continuously adjusts power, speed, and material feed rate to optimize both productivity and microstructure quality. This dynamic adjustment allows the process to maintain high deposition rates while preventing defect formation through real-time parameter optimization, resolving the contradiction between productivity and reliability
Solution Approach 2:
The patent utilizes feedback control mechanisms to monitor and adjust process parameters during directed energy deposition. By measuring actual deposition characteristics and microstructure formation in real-time, the system can adjust energy input and deposition rate to prevent flaw formation while maintaining high productivity. This closed-loop control resolves the contradiction by enabling high-speed deposition with controlled microstructure quality
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 method allows for precise repair or modification of high temperature components while maintaining target mechanical properties and microstructure, reducing flaws and ensuring the components meet predetermined specifications.
Implementation Method 1
an energy source directed at the component to advance an energy beam along a first path to form an advancing molten pool on the component
Data Source
AI summary
Example systems may include an energy source, a material delivery device, and a computing device. The computing device, based on a target height of a layer deposited on a component by directed energy deposition, may control an energy source directed at a component and may control a material delivery device. Controlling the energy source may include advancing an energy beam along a first path to form an advancing molten pool on the component. Controlling the material delivery device may include delivering a material to the advancing molten pool. The material may combine with the advancing molten pool to form a first raised track having an actual height. The layer may include the first raised track. A deposited region of the component may include the layer. The actual height may affect a resultant microstructure within the deposited region.