Gas Turbine Diaphragm Rail Cladding for Selective Wear Repair
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Solution Overview
Problem
Current methods for repairing turbomachine diaphragms are inefficient and costly, as they often require extensive machining and replacement of entire components, which can lead to increased operational costs and reduced service life.
Innovation Solution
A method involving machining worn areas of the diaphragm rail to create a clean, geometrically exact surface, followed by cladding with a filler material such as austenitic stainless steel, which is then machined to match nominal dimensions, allowing only worn parts to be repaired and reducing unnecessary machining and cladding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If entire diaphragm components are replaced during repair, then reliability is improved, but loss of substance increases and productivity decreases
Solution Approach 1:
The repair process segments the diaphragm into worn and non-worn areas, applying repair operations only to the affected segments rather than the entire component. This is achieved by selectively machining and cladding only the worn coupon areas while preserving the remaining serviceable portions of the diaphragm rail member.
Solution Approach 2:
The invention applies local quality by providing different treatments to different areas of the diaphragm. Worn areas receive machining and cladding operations to restore their dimensions and properties, while non-worn areas are left untouched, maintaining their original properties and avoiding unnecessary material removal.
2Manufacturing precision
If extensive machining is performed on the entire diaphragm, then manufacturing precision is improved, but productivity decreases and loss of time increases
Solution Approach 1:
The invention applies partial action by performing machining operations only to the extent necessary to remove worn material and create a clean surface for cladding. The machining is limited to the worn coupon areas rather than the entire diaphragm, reducing the total volume of material removed and the time required for the repair process.
3Duration of action of stationary object
If complete diaphragm replacement is performed, then service life is extended, but loss of time increases and productivity decreases
Solution Approach 1:
The repair process incorporates preliminary actions by performing surface preparation, including machining and cleaning operations, before applying the cladding material. This ensures that the cladding adheres properly to the substrate, creating a durable repair that extends service life without requiring complete component replacement.
4Productivity
If worn areas are selectively repaired instead of complete replacement, then productivity improves and loss of substance decreases, but manufacturing precision requirements increase
Solution Approach 1:
The cladding material serves as an intermediary between the worn substrate and the required dimensional specifications. The cladding is applied to the machined surface and then machined down to the final dimensions, providing a buffer that allows for precise dimensional control while working with selectively repaired areas rather than complete component replacement.
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 extends the service life of the repaired diaphragm beyond that of a new one, reduces costs by targeting only worn areas, and ensures improved operational efficiency by maintaining precise dimensions and reducing mechanical stress through strategic welding.
Implementation Method 1
the filler material is welded to at least one machined surface of the diaphragm rail member such that a cladding is formed
Data Source
AI summary
A method of refurbishing worn diaphragm rails for turbo machines. This method comprises machining the worn part of the diaphragm rails such that a clean and geometrically exact machined surface is achieved. Welding one or more layers on these machined surfaces builds up a cladding that overtops the nominal dimensions of new diaphragm. The method further comprises machining the cladding such that it has the nominal dimensions of a new diaphragm.