Gas Turbine Combustor Float Wall Panel Repair via Percussion Welding
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Solution Overview
Problem
Gas turbine engine combustor float wall panels suffer from damage due to high temperatures, oxidation, corrosion, and erosion, leading to high maintenance and replacement costs, as existing methods do not provide a reliable repair solution.
Innovation Solution
A method involving the separation and repair of combustor float wall panels using percussion welding to attach and trim cooling pins, allowing for the construction of a supplemental body and matching the existing panel's contour, enabling the panel to be restored and reused.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If combustor float wall panels are replaced when damaged, then reliability is improved, but loss of substance and cost increase
Solution Approach 1:
The patent recovers and reuses the undamaged portions of the combustor float wall panel by cutting out only the damaged section and fabricating a supplemental body to replace the removed portion. This allows the majority of the original panel material to be recovered and continued in service, rather than discarding the entire panel.
Solution Approach 2:
The repair process segments the panel into damaged and undamaged portions, treating them differently. The damaged section is removed while the undamaged section is retained and integrated with a newly fabricated supplemental body, allowing selective replacement rather than complete replacement.
2Reliability
If whole panels are replaced when damaged, then reliability is improved, but productivity decreases due to downtime
Solution Approach 1:
By recovering and reusing the undamaged portions of the panel, the repair process significantly reduces the time required compared to complete panel replacement. The engine can be taken out of service for a shorter duration, minimizing productivity loss while still restoring reliability.
Solution Approach 2:
Instead of replacing the entire panel (excessive action), the patent applies partial action by replacing only the damaged portion with a supplemental body. This reduces the scope of work required, shortens maintenance time, and improves productivity while achieving the necessary reliability restoration.
3Manufacturing precision
If cooling pins are removed and reattached during repair, then manufacturing precision is improved, but device complexity increases
Solution Approach 1:
The cooling pins are removed before fabricating the supplemental body and then reattached in a predetermined pattern. This preliminary removal allows for precise positioning and alignment during reattachment, ensuring manufacturing precision while the structured approach keeps the process manageable.
Solution Approach 2:
The cooling pins are reattached with specific attention to their predetermined pattern and positioning on the supplemental body. This local quality control ensures that the critical cooling function is restored with proper alignment, while the overall process complexity is managed through systematic procedures.
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 effectively extends the life of combustor float wall panels by allowing for repair and reconstruction, reducing the need for full panel replacement and lowering maintenance and repair costs for gas turbine engines.
Implementation Method 1
The cooling pin may be attached to the supplemental body using any suitable method, such as by percussion welding
Data Source
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AI summary
According to one embodiment of the present disclosure, a method for working a combustor float wall panel is disclosed. The method may comprise providing a supplemental body of a combustor float wall panel, and attaching at least one cooling pin to the supplemental body. According to another embodiment, a method for working a combustor float wall panel of a gas turbine engine is disclosed. The method may comprise separating a combustor float wall panel from a combustor of a gas turbine engine, providing a supplemental body to the combustor float wall panel, attaching at least one cooling pin to the supplemental body; and returning the combustor float wall panel to the combustor of the gas turbine engine.