Engine Case Flange Repair by Replacing Damaged Attachment Tabs
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Solution Overview
Problem
The existing methods for maintaining gas turbine engine cases are inefficient, as damaged attachment tabs often lead to the scrapping of entire engine cases, resulting in high costs due to the integral nature of these tabs within the flange structure, which are difficult to repair without compromising the integrity of the case.
Innovation Solution
A method for repairing a gas turbine engine case flange involves removing damaged attachment tabs, producing a replacement flange portion with integral tabs, and securing it to the remaining flange portion, using materials like stainless steel for durability and processes such as milling or 3-D printing for fabrication.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If damaged attachment tabs are repaired by replacing the entire case, then structural integrity is maintained, but cost increases significantly and material is wasted
Solution Approach 1:
The flange is divided into a damaged portion and a remaining portion. Only the damaged portion containing the attachment tabs is removed and replaced, while the majority of the flange structure is retained. This segmentation allows repair of only the necessary section rather than replacing the entire case, reducing material waste while maintaining structural integrity.
Solution Approach 2:
The damaged attachment tabs and their corresponding damaged flange portion are extracted from the case. A replacement flange portion is then produced and installed in their place. This extraction approach removes only the defective elements while preserving the sound portions of the case.
2Reliability
If damaged attachment tabs lead to scrapping the entire case, then reliability is maintained, but cost increases significantly
Solution Approach 1:
Instead of discarding the entire case when attachment tabs are damaged, the method recovers value by removing only the damaged flange portion and replacing it. The majority of the case and flange structure is recovered and continues to serve its function, significantly reducing the cost impact compared to complete case replacement.
3Strength
If attachment tabs are integral to the flange and case, then structural strength is maintained, but repairability decreases
Solution Approach 1:
The flange is segmented into replaceable and non-replaceable portions. The damaged portion containing the integral attachment tabs is designed to be removable as a separate component, while the main flange structure remains intact. This allows the integral design to maintain strength while enabling targeted repair of the damaged segment.
4Reliability
If the entire flange is replaced when tabs are damaged, then reliability is ensured, but productivity decreases due to extended downtime
Solution Approach 1:
Instead of replacing the entire flange (excessive action), only the damaged portion is replaced (partial action). This partial replacement approach achieves the necessary reliability restoration while significantly reducing the time and resources required for the repair process, thereby improving engine availability and productivity.
Data Source
AI summary
The present disclosure provides a system and method of repairing a flange of an engine case having a damaged section of attachment tabs and/or flange region. One or more damaged attachments tabs extending away from a flange are removed along with a first portion of the flange, thus leaving a second portion of the flange. A replacement component is produced comprising a replacement flange portion and one or more replacement tabs. The replacement flange portion is placed in contact with the second portion of the flange and the replacement flange portion is secured to the second portion of the flange.