Turbomachine Overhung Section Repair by Angled Layer Deposition
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Solution Overview
Problem
Current methods for manufacturing and repairing turbomachine parts with overhung sections, such as flared tip turbomachine blades, are limited as they require replacement rather than repair, and existing additive manufacturing techniques struggle to accurately form complex geometries like overhung sections.
Innovation Solution
A method involving the sequential layering of material layers at acute angles relative to the longitudinal axis of the part, followed by machining, to form or repair overhung sections on turbomachine parts, allowing for the creation of complex geometries and extending the lifespan of these parts.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If traditional casting or additive manufacture is used to build up material in the vertical or radial direction, then material can be added to form overhung sections, but the manufacturing precision and geometric accuracy of complex overhung geometries deteriorate
Solution Approach 1:
The patent transitions from vertical/radial layering to circumferential layering of material around the overhung section. By depositing material in the circumferential direction (perpendicular to the traditional build direction), the process achieves both material addition capability and high geometric precision, as each circumferential layer naturally conforms to the rotational symmetry of the overhung geometry
Solution Approach 2:
The manufacturing process is segmented into multiple circumferential passes, where material is deposited in discrete angular segments that are gradually built up to form the complete overhung section. This segmentation allows for precise control of each layer's geometry while maintaining the overall complex shape accuracy
2Ease of manufacture
If traditional manufacturing methods are used for flared tip turbomachine blades, then material can be added in radial direction, but repair capability is lost and replacement is required
Solution Approach 1:
The patent enables recovery and reuse of the overhung section by providing a method to add material and repair damaged geometries. Instead of discarding and replacing the entire blade when the overhung section is damaged, the circumferential layering process allows selective material addition to restore or repair the overhung geometry, extending component life
Solution Approach 2:
The circumferential layering process is designed to be self-correcting for geometric errors, as each circumferential pass can be independently controlled and adjusted. The process inherently maintains geometric accuracy through the rotational symmetry of the deposition path, allowing repair without requiring complex external fixtures or alignment procedures
3Ease of manufacture
If conventional additive manufacturing is used to form overhung sections, then material can be added, but the ability to create complex geometries with acute angle layers deteriorates
Solution Approach 1:
The patent deposits material in the circumferential direction (tangential to the rotational axis) rather than in the radial or axial direction. This dimensional change allows the formation of complex three-dimensional overhung geometries with acute angle layers, as each circumferential deposit naturally creates the desired angular orientation relative to the longitudinal axis
Solution Approach 2:
The manufacturing process is dynamic and adaptive, with the deposition path and layer orientation adjusted in real-time based on the desired final geometry. The system can vary the circumferential deposition pattern to create different acute angles and complex shapes, rather than being constrained to fixed layer orientations
Data Source
AI summary
Method of forming or repairing a part with an overhung section. The method may include removing a portion, and adding a section to the part. The section includes the overhung section. The adding includes sequentially layering at least one plurality of material layers on the part, the at least one plurality of material layers approximating dimensions of the section including the overhung section. The sequential layering may include, for example, laser welding, and may be carried out in a number of ways that create varied layers within the overhung section. The method may include machining the at least one plurality of material layers to form the section including the overhung section.