Magnetic Blade Fixturing for Batch Additive Repair Alignment
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Solution Overview
Problem
Existing repair processes for compressor blades in gas turbine engines are labor-intensive, time-consuming, and costly, particularly due to the need for tedious post-processing and lack of efficiency in repairing multiple components simultaneously using traditional welding/cladding or direct-energy-deposition methods.
Innovation Solution
A tooling assembly for a powder bed additive manufacturing machine that securely mounts multiple compressor blades in precise, uniform orientation, utilizing a vision system to determine repair toolpaths and depositing additive powder layers for fusion, enabling efficient and accurate repair of multiple blades simultaneously.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If traditional welding/cladding technique is used to repair compressor blades, then repair materials can be bonded to blade tips, but the process requires tedious post-processing including heavy machining and secondary polishing to achieve target geometry and surface finish
Solution Approach 1:
The patent replaces traditional mechanical welding/cladding processes with a powder bed additive manufacturing process. Instead of using focused power sources to melt and bond repair materials mechanically, the system uses a powder bed fusion approach where additive powder is selectively melted and fused directly onto blade tips layer by layer, eliminating the need for subsequent heavy machining and polishing operations
Solution Approach 2:
The patent changes the fundamental parameters of the repair process by transitioning from bulk material deposition (welding/cladding) to layer-by-layer additive fabrication. This parameter change enables precise geometric control during the repair process itself, eliminating the need for post-processing machining while maintaining strong bonds between repair materials and blade tips
2Ease of repair
If traditional welding/cladding technique is used for blade repair, then single blade repair can be performed, but the process is very labor intensive and results in very large overall labor costs
Solution Approach 1:
The patent merges multiple individual blade repair operations into a single batch processing operation. Multiple compressor blades are positioned simultaneously on a build platform and repaired together in one additive manufacturing cycle, transforming the process from sequential single-blade repair to parallel multi-blade repair, thereby dramatically increasing productivity and reducing labor costs
3Ease of manufacture
If direct-energy-deposition methods are used for blade repair, then repair can be performed on blade tips, but the methods are not suitable for batch processing or repairing a large number of components in a time efficient manner
Solution Approach 1:
The patent replaces direct-energy-deposition methods with powder bed additive manufacturing. Instead of directing high-speed metal powders to bombard and deposit on individual blade tips sequentially, the system uses a powder bed fusion process where layers of additive powder are spread across the build platform and selectively melted, enabling simultaneous repair of multiple blades in a batch processing mode
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 solution significantly reduces labor costs and time by allowing for precise, batch processing of multiple compressor blades, improving repair efficiency and surface finish while maintaining the structural integrity of the blades.
Implementation Method 1
a magnet assembly securing each of the component fixtures to the mounting plate in a desired position and orientation
Implementation Method 2
a magnet assembly securing each of the component fixtures to the mounting plate in a desired position and orientation
Implementation Method 3
irradiating the layer of additive powder with a focused power source to fuse the layer of additive powder onto the component
Implementation Method 4
The repair materials are melted by focused power source (e.g., laser, e-beam, plasma arc, etc.) and bonded to blade tips
Data Source
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AI summary
A tooling assembly (200) for mounting a plurality of components (70), such as compressor blades (70), in a powder bed additive manufacturing machine (100) to facilitate a repair process is provided. The tooling assembly (200) includes component fixtures (202) configured for receiving each of the compressor blades (70), a mounting plate (210) for receiving the component fixtures (202), and a magnet assembly (220) operably coupling the component fixtures (202) to the mounting plate (210) in a desired position and orientation to facilitate an improved printing process.