Internal Defect Repair by Converging Multi-Beam Irradiation
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Internal defects such as porosity, lack of melting, and cracks in manufactured parts, particularly in aeronautics, are not effectively addressed by existing methods, leading to premature failure and part scrapping, as current detection and repair techniques are inadequate for internal defects within the material.
Innovation Solution
A method involving the detection and localization of internal defects, followed by simultaneous irradiation with multiple converging beams to apply energy below the sintering threshold for each beam but above the transformation threshold when combined, allowing for selective sintering or melting within a target volume without external material addition, using non-destructive techniques like tomography or X-rays for precision.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a single high-energy beam is used to treat internal defects, then the transformation threshold can be reached, but the material may be damaged or overheated in surrounding areas
Solution Approach 1:
The treatment process is segmented into multiple independent beam sources, each delivering a fraction of the total required energy. Multiple beams (at least two, preferably three) are directed simultaneously at the target volume, with each beam's energy individually controlled to remain below the material's transformation threshold. The cumulative effect of all beams together achieves the necessary transformation temperature, thereby treating the defect while preventing localized overheating or damage that would result from a single high-energy beam.
2Object-affected harmful factors
If multiple beams are used to reduce energy per beam, then material damage is prevented, but the complexity of the treatment system increases
Solution Approach 1:
Multiple independent beam systems are merged into a coordinated treatment process. Each beam is independently controllable and targeted, but their combined effect produces the therapeutic transformation. The system integrates multiple beam sources, positioning systems, and energy control mechanisms that work together synergistically, where the sum of individual beam energies equals the required transformation energy while maintaining simplicity through modular design.
Solution Approach 2:
The system changes the energy parameter distribution by dividing the total required energy into multiple smaller portions delivered by separate beams. Each beam operates at a lower energy level (below transformation threshold) while collectively achieving the necessary cumulative energy input. This parameter redistribution allows the use of simpler, more controlled beam sources rather than requiring a single complex high-energy system.
3Manufacturing precision
If the target volume is precisely defined to include only the defect, then treatment precision is improved, but the defect may not be fully eliminated
Solution Approach 1:
The target volume is defined with local quality differentiation: the core region contains the defect to be eliminated, while the peripheral region includes surrounding healthy material. This deliberate inclusion of a buffer zone ensures complete defect elimination through thermal diffusion and phase transformation that extends beyond the immediate defect boundaries. The local quality varies within the target volume, with the center receiving maximum energy concentration and the periphery receiving gradient energy that prevents sharp thermal boundaries.
4Object-affected harmful factors
If the energy per beam is kept below the transformation threshold, then material damage is avoided, but the treatment time increases
Solution Approach 1:
The treatment process maintains continuous energy input through simultaneous operation of multiple beams. Rather than sequential application that would extend treatment time, all beams operate concurrently to deliver their respective energy portions at the same time. This continuous, parallel action achieves the cumulative transformation energy much faster than sequential methods while keeping each individual beam's energy density below the damage threshold through sustained, coordinated exposure.
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 enables the repair of internal defects in three dimensions within the part, effectively eliminating defects without external material addition, thereby extending the part's lifespan and preventing premature failure.
Implementation Method 1
the energy applied to the target volume by each beam is less than a threshold energy for sintering the material, and the sum of the energies applied to the target volume by each one of the beams is greater than or equal to a transformation threshold energy
Implementation Method 2
the transformation threshold energy corresponding to the threshold energy for sintering the material, when it is desired to obtain a selective sintering of the material in the target volume
Implementation Method 3
or to the threshold energy for melting the material, when it is desired to obtain a selective melting of the material in the target volume
Implementation Method 4
wherein the material of the part is partially transparent to said at least two beams
Data Source
AI summary
A method for treating an internal defect in a part made of a material, involves: a) detecting and locating the internal defect in the part; b) defining, inside the part, at least one target volume which at least partially includes the defect; c) for each target volume, simultaneously irradiating the target volume by at least two beams which converge in the target volume and are continuous, whereby a treated area is obtained. The energy applied to the target volume by each beam is less than a threshold energy for sintering the material, and the sum of the energies applied to the target volume by each of the beams is greater than or equal to a transformation threshold energy that corresponds to the threshold energy for sintering or melting the material; the material of the part is partially transparent to said beams.