Laser Cladding Variable Bead Width for Turbine Repair
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Solution Overview
Problem
Current laser cladding techniques for manufacturing and repairing turbine components, such as BLISKS and compressor blades, suffer from imperfections and porosity due to incomplete fusion between layers and complex geometries, leading to costly rejections and reduced performance.
Innovation Solution
The implementation of an Adaptive Tool Path Deposition Method in Laser Net Shape Manufacturing (LNSM) that uses a variable bead width with a constant overlap ratio, controlled by transfer functions for laser power, tool velocity, and powder feed rate, to ensure precise and strong layer formation, eliminating fusion imperfections and porosity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of substance
If laser cladding is used to manufacture turbine components, then material efficiency is improved, but fusion imperfections and porosity occur due to incomplete layer fusion
Solution Approach 1:
The patent implements dynamic adjustment of laser parameters (power, speed, focus position) during the cladding process to optimize melting and fusion conditions for each specific geometry and layer, ensuring complete fusion without porosity while maintaining material efficiency
Solution Approach 2:
The system incorporates real-time monitoring and feedback control of laser parameters and process conditions to detect and correct fusion imperfections during manufacturing, ensuring consistent quality and reducing porosity
2Manufacturing precision
If conventional machining is used to create BLISKS, then manufacturing precision is improved, but production cost and time increase significantly
Solution Approach 1:
The patent uses preliminary 3D modeling and simulation to optimize the laser cladding process parameters and toolpaths before actual manufacturing, ensuring high precision blades are built correctly the first time without requiring extensive post-machining
Solution Approach 2:
The patent replaces conventional mechanical machining with laser-based additive manufacturing, eliminating the need for extensive material removal while achieving comparable or superior precision through controlled material deposition
3Strength
If damaged blades are repaired by welding and machining, then blade integrity is restored, but performance and durability are reduced
Solution Approach 1:
The patent modifies laser processing parameters (power density, scanning speed, atmosphere control) during repair to create optimal fusion conditions that restore blade integrity while maintaining the metallurgical properties and performance characteristics of the original material
4Device complexity
If fixed laser parameters are used in cladding, then process simplicity is maintained, but fusion imperfections occur due to varying geometry requirements
Solution Approach 1:
The system dynamically adjusts laser parameters based on real-time feedback and pre-programmed profiles that account for varying geometry, ensuring optimal fusion quality across different parts of the component without requiring overly complex manual control
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 accurate fabrication and repair of turbine components with reduced imperfections, achieving near-net shape specifications and maintaining performance, reducing material waste and labor costs associated with post-machining processes.
Implementation Method 1
a laser is used to create a 3D geometry by precisely cladding thin layers of metal powder on a base material
Implementation Method 2
melts powders by feeding the power into molten material on a surface that has been irradiated by a laser beam
Implementation Method 3
these layers are built upon one another to form new parts or to repair damaged parts
Data Source
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AI summary
A method is disclosed for laser cladding a substrate 3, comprising providing the substrate 3; depositing a first determined variable bead width of a material along a toolpath upon the substrate; depositing a second adjacent determined variable bead width of a material along the toolpath which overlaps the first determined variable bead width of deposited material 7; continuing to deposit a plurality of overlapping predetermined adjacent variable bead widths of a material until a first material layer is complete; forming a second material layer by depositing a plurality of overlapping predetermined variable bead widths of a material on top of the first material layer; and continuing to deposit material layers on top of deposited material layers until the cladding is complete; wherein the variable bead width of the deposited material is controlled by a computer having a plurality of input parameters to maintain an approximately constant percent of bead width overlap.