Flared Tip Turbomachine Blade Repair Using Layered Overhang Build-Up
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Solution Overview
Problem
Current methods for manufacturing and repairing turbomachine parts with overhung sections, such as flared tip turbomachine blades, are limited, as traditional techniques require replacement rather than repair, and existing repair methods are not feasible, leading to inefficiencies and increased costs.
Innovation Solution
A method involving the sequential layering of material layers using techniques like laser welding, cold metal transfer, or additive manufacturing to form or repair overhung sections, allowing for the creation of new sections that approximate the dimensions and shape of the original, while also enabling machining to refine the structure and extend the part's lifespan.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If traditional casting or additive manufacture is used to build up material in the vertical or radial direction, then the part can be formed or repaired, but the method cannot create overhung sections that extend circumferentially beyond the airfoil
Solution Approach 1:
The patent transitions from building material only in the vertical/radial direction to adding material in both radial and circumferential directions. This dimensional expansion enables the creation of overhung sections that extend beyond the airfoil, resolving the limitation of traditional methods while maintaining manufacturing feasibility through controlled material deposition processes
2Ease of repair
If flared tip turbomachine blades are damaged, then replacement is required, but replacement increases cost and downtime without allowing repair
Solution Approach 1:
The patent enables recovery of damaged flared tip blades by removing damaged portions and adding new material to restore the original geometry. This repair capability eliminates the need for complete replacement, reducing both cost and downtime while maintaining blade performance through precise material addition and machining processes
3Adaptability or versatility
If material is added in both circumferential and radial direction to form flared tip, then the overhung section can be created, but the process becomes more complex compared to traditional two-dimensional build-up
Solution Approach 1:
The patent divides the complex three-dimensional material addition process into sequential steps: first removing damaged portions, then adding material in controlled layers in both radial and circumferential directions, and finally machining to precise tolerances. This segmentation of the manufacturing process makes the complex task of creating overhung sections manageable and repeatable
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 approach enables the repair and formation of turbomachine parts with enhanced performance and longevity, reducing the need for replacement and minimizing post-processing requirements, thereby improving operational efficiency and extending the life of the parts.
Implementation Method 1
The adding includes laser welding, cold metal transfer (CMT), additive manufacture, or a combination thereof
Implementation Method 2
The adding includes laser welding, cold metal transfer (CMT), additive manufacture, or a combination thereof
Data Source
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AI summary
Method of forming or repairing a part with an overhung section. The method may include removing a portion, and adding a section to the part. The section includes the overhung section. The adding includes sequentially layering at least one plurality of material layers on the part, the at least one plurality of material layers approximating dimensions of the section including the overhung section. The sequential layering may include, for example, laser welding, and may be carried out in a number of ways that create varied layers within the overhung section. The method may include machining the at least one plurality of material layers to form the section including the overhung section.