Hole Closing in Metal Articles Using Extracted Support Surface
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Solution Overview
Problem
Closing holes in metal articles, particularly in precision components like gas turbine buckets, is challenging due to material deposition issues with welding and high costs associated with pre-sintered preform plugs.
Innovation Solution
A method involving the removal of a portion of the metal article surrounding the hole to create a support surface, where a metal support structure is inserted and fused with a metal composition applied within the hole, effectively closing the hole without material deposition into internal channels.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If welding techniques are used to close the hole, then the hole can be closed, but material is deposited into the internal channel or cavity beneath the hole
Solution Approach 1:
The invention extracts or removes the problematic portion of the metal article surrounding the hole to create a support surface. This support surface then supports a metal support structure that prevents material from being deposited into the internal channel or cavity during the closing process, thereby eliminating the harmful effect while maintaining the hole closing function.
2Ease of manufacture
If pre-sintered preform plugs are used to close the hole, then the hole can be closed, but the cost increases due to high cost of pre-sintered preform material and precise machining
Solution Approach 1:
The invention replaces expensive pre-sintered preform plugs with a metal support structure that can be formed from less costly materials. The support structure serves its function during the closing process and can be consumed or integrated into the final product, eliminating the need for expensive pre-sintered materials and precise machining operations.
3Ease of manufacture
If pre-sintered preform plugs are used to close the hole, then the hole can be closed, but the process becomes economically inefficient due to precise machining required
Solution Approach 1:
The invention creates a support surface by removing material that replicates or copies the geometry needed to support the closing process. This support surface then supports a metal support structure that eliminates the need for precisely machining expensive pre-sintered plugs, as the support structure can be formed with less stringent precision requirements.
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 reduces costs, increases process control, and enhances efficiency by avoiding material deposition and eliminating the need for expensive pre-sintered preform plugs, while ensuring a flush and crack-free closure.
Implementation Method 1
a metal composition is applied into the hole and onto the metal support structure. The metal support structure, the metal composition, and the metal article are fused together
Data Source
AI summary
A method for closing a hole penetrating a hole height from a first surface of a metal article through a second surface of the metal article is disclosed including removing a portion of the metal article surrounding the hole from the metal article. The portion includes a depth extending from the first surface into the metal article and terminating prior to the second surface. Removing the portion forms a support surface within the hole adjacent and opposite to the second surface. A metal support structure is disposed within the hole on the support surface, and a metal composition is applied into the hole and onto the metal support structure. The metal support structure, the metal composition, and the metal article are fused together.