Induction Brazing Coil Repair for Load-Bearing Treatment Areas

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Solution Overview

Problem

Conventional methods for repairing load-bearing components, such as gas turbine components, require placing the entire component in a furnace, which is expensive and time-consuming.

Innovation Solution

A method involving the use of a portable induction brazing coil to heat a repair material applied to the treatment area of a load-bearing component, creating a brazed joint without the need for a furnace, utilizing a repair material with specific compositions and an induction coil geometry tailored to the component.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If conventional furnace brazing is used to repair load-bearing components, then the brazed joint can be achieved, but the repair process becomes expensive and time-consuming

Engineering Contradiction:

Improvebrazed joint qualityVSAvoidrepair time

Core Design Contradiction:

ReliabilityVSLoss of time

Solution Approach 1:

The patent applies localized induction heating to only the treatment area requiring repair, rather than heating the entire component in a furnace. The portable induction brazing coil concentrates thermal energy precisely where needed, achieving the brazing temperature in the treatment area while leaving the rest of the component at ambient or lower temperature. This localized approach dramatically reduces repair time and energy consumption while maintaining brazed joint quality.

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The patent extracts the heating function from the conventional furnace system and implements it through a portable induction brazing coil that can be brought to the treatment area. This separation allows the brazing process to occur in-place without requiring the entire component to be placed in a large, expensive furnace, thereby reducing both time and cost while achieving the same brazing result.

Inventive Principle:

Principle #2Taking out (Extraction)

2Reliability

If conventional furnace brazing is used to repair load-bearing components, then the brazed joint can be achieved, but the repair cost increases

Engineering Contradiction:

Improvebrazed joint qualityVSAvoidrepair cost

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The patent replaces the mechanical furnace heating system with an electromagnetic induction heating system. The portable induction brazing coil uses electromagnetic fields to generate heat directly in the treatment area through eddy currents, eliminating the need for thermal convection and radiation from a furnace. This substitution reduces energy loss and equipment cost while maintaining brazing quality.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

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 the expense and time required for repairs by allowing localized heating, enabling efficient brazing of load-bearing components without the need for a furnace, thus saving resources and improving repair efficiency.

Implementation Method 1

positioning an induction brazing coil having a geometry corresponding to the treatment area over the repair material and the treatment area. The method further includes heating the repair material utilizing the induction brazing coil

Methodology Applied

Scientific EffectElectromagnetic induction: Electromagnetic Induction

Implementation Method 2

heating the repair material utilizing the induction brazing coil to a temperature sufficient to cause at least partial melting of the repair material

Methodology Applied

Scientific EffectEddy currents: Eddy Currents

Implementation Method 3

heating the repair material utilizing the induction brazing coil to a temperature sufficient to cause at least partial melting of the repair material, thereby effecting a brazed joint

Methodology Applied

Scientific EffectMelting: Melting

Data Source

PatentUS11039507B2Method of brazing a treatment area of a load-bearing component

Publication Date: 2021.06.15 GE INFRASTRUCTURE TECH LLC

AI summary

A method of brazing a treatment area of a load-bearing component includes applying a repair material over the treatment area of the component and positioning an induction brazing coil having a geometry corresponding to the treatment area over the repair material and the treatment area. The method further includes heating the repair material utilizing the induction brazing coil to a temperature sufficient to cause at least partial melting of the repair material, thereby effecting a brazed joint between the treatment area and the repair material.