Aircraft Fuselage Repair Using Additive Layer Manufacturing
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Solution Overview
Problem
Conventional repair methods for fuselage components of aircraft and spacecraft are complex, costly, and often compromise the structural integrity and outer shape of the components, requiring additional materials like glue and rivets, and introducing internal stress.
Innovation Solution
A method using additive layer manufacturing (ALM) to remove damaged material, attach a doubler, and fill the recess with a filler material, reducing the need for external fasteners and maintaining the component's structural properties, with optional laser shock peening for enhanced fatigue resistance and crack prevention.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If conventional repair methods using riveted or glued patches are used, then the damaged area can be covered, but the outer shape of the component is changed and additional materials (glue, rivets) are required
Solution Approach 1:
The patent replaces conventional mechanical repair methods (riveting, gluing) with additive layer manufacturing technology. This substitution eliminates the need for additional fasteners and adhesives, directly reconstructing the missing material to restore the original component shape and structural integrity without modifying the outer surface geometry
Solution Approach 2:
The invention changes the material deposition process from subtractive (removing damaged material) to additive (depositing material layer by layer). By controlling deposition parameters such as layer thickness, deposition rate, and thermal parameters, the method restores the original component geometry while minimizing residual stresses and maintaining structural properties
2Strength
If conventional repair methods with multiple patches are used, then the damaged area can be reinforced, but the device complexity and cost increase
Solution Approach 1:
The patent merges multiple repair operations (material removal, surface preparation, material deposition, and reinforcement) into a single integrated additive manufacturing process. This consolidation eliminates the need for separate patch application, adhesive bonding, and fastening operations, thereby reducing procedural complexity while maintaining or enhancing structural integrity
Solution Approach 2:
The invention utilizes composite material deposition capabilities in additive manufacturing to create functionally graded repair zones. By varying material composition and properties during the deposition process, the method achieves optimized structural integrity in different regions of the repair zone without requiring multiple separate components or assembly steps
3Reliability
If conventional repair methods are used, then the damaged structure can be replaced, but internal stress is introduced into the component
Solution Approach 1:
The patent employs periodic, controlled heating and cooling cycles during additive layer manufacturing to manage thermal gradients and minimize residual stress accumulation. By depositing material in incremental layers with controlled inter-pass heating, the process reduces thermal shock and prevents the introduction of significant internal stresses that would compromise structural behavior
Solution Approach 2:
The invention optimizes deposition parameters including layer thickness, deposition rate, and thermal parameters to control heat input and minimize residual stress. By adjusting these parameters, the method achieves low energy input per layer, preventing the creation of high stress peaks while maintaining material properties and structural integrity
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 a lightweight, stress-reduced repair that maintains the original shape and structural behavior of the component, offering improved fatigue resistance and local reinforcement without the need for additional fasteners or glue, making it more efficient and cost-effective than traditional methods.
Implementation Method 1
removing component material in a region around a damaged area to form a recess
Implementation Method 2
filling the recess with a filler material using additive layer manufacturing
Implementation Method 3
laser shock peening may be employed during the repair, thereby improving the fatigue resistance of the repaired component
Data Source
Figure 1~3
Figure 4(a)~6
AI summary
The present invention pertains to a method for repairing a fuselage component (1) of an aircraft or spacecraft, the method comprising removing component material in a region (2)around a damaged area to form a recess (3) in the fuselage component, attaching at least one doubler (5) to one surface of the fuselage component (1), the at least one doubler (5) covering the region around the damaged area (2), and filling the recess (3) with a filler material using additive layer manufacturing, ALM.