Laser Cladding Repair for Turbomachine Narrow Recesses
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Solution Overview
Problem
Conventional laser cladding methods are inefficient for repairing stator cases of turbomachines due to difficulties in accessing narrow recesses and the need to remove stator blades, which limits the application of laser cladding in these areas.
Innovation Solution
A laser cladding method and machine that uses a robotic arm with a laser source, powder feeder, and air source to deliver a laser beam and cladding material along an angular path, allowing for efficient repair of turbomachine components with narrow recesses without removing stator blades, by converging the laser beam, powder jet, and air jet on the repair area, and using a flexible air tube to remove excess powder.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of repair
If conventional laser cladding methods are used to repair stator cases, then the repair process requires removal of stator blades to access narrow recesses, but this increases repair time and complexity
Solution Approach 1:
The repair process is segmented into discrete angular positions (e.g., 45°, 90°, 135°, 180°) around the stator case. The robotic arm systematically moves to each position, performs cladding operations, and then proceeds to the next position. This segmentation allows precise control of the repair process without requiring blade removal, as each position can be accessed independently through the narrow recesses.
2Length of stationary object
If conventional laser cladding is used with standard beam lengths, then the laser beam cannot reach narrow recesses, but extending the beam length reduces precision and control
Solution Approach 1:
The system employs dynamic positioning and control of the robotic arm to adjust the laser beam delivery angle and position in real-time. The robotic arm can tilt and position the laser source at optimal angles to reach into narrow recesses while maintaining precise control of the beam placement. This dynamic adjustment allows long beam reach without sacrificing precision, as the system adapts its configuration to each specific repair location.
3Productivity
If thicker cladding layers are deposited to rebuild greater damaged volume, then repair speed increases, but control of layer quality and homogeneity becomes more difficult
Solution Approach 1:
The robotic arm performs continuous cladding operations at each angular position without interruption, depositing material in a continuous motion along predefined paths. This continuous action ensures uniform layer thickness and homogeneity, as the laser parameters (power, speed, focus) are maintained consistently throughout each pass. The system can then proceed to the next angular position and repeat the process, building up thicker layers through multiple passes while maintaining quality control through systematic repetition of the optimized process parameters.
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
Enables quick and efficient rebuilding of damaged volumes with thicker layers, maintaining mechanical properties of the component, and avoiding the need to remove stator blades during repair, thus improving the repair process for turbomachine components with narrow recesses.
Implementation Method 1
Laser cladding uses a laser beam to fuse a cladding material having desired properties into the base material of a component whose surface is to be repaired
Implementation Method 2
an air source (4) including a flexible tube (40) attached to the robotic arm (1a) in such a way that the air source (4) is positionable in close proximity to the nozzle (30) of the powder feeder (3) when following the predetermined path (P), in order to direct an air jet (4a) towards the area to be repaired
Data Source
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AI summary
A method (100) for repairing a turbomachine component (C) comprises the steps of: setting up (110) a laser cladding machine (1) including a laser source (2) a powder feeder (3) and an air source (4), for repairing a narrow recess of the turbomachine component; defining a path (120) including areas to be repaired by laser cladding within the narrow recess; moving forward (130) the laser cladding machine (1) or the turbomachine component (C), in order that said path is covered from the first to the second end point by the laser beam (2a) and the powder jet (3a) for repairing said areas to be repaired; moving backward (130) the laser cladding machine (1) or the turbomachine component (C), in order that said path is covered from the second to the first end point by the air jet (4a) for blowing away the powder in excess.