Adaptive Toolpath Repair for Powder-Built Component Restoration
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Solution Overview
Problem
Complex components, such as those in gas turbine engines, require efficient repair methods to reduce replacement costs, as existing weld filler application processes are not fully optimized for precision and effectiveness.
Innovation Solution
A method combining structured light scanning, additive manufacturing, and machining to create a component by depositing powder based on additive manufacturing data, determining predicted characteristics, and comparing them to reference data to generate machining data for precise repair or manufacturing, using different materials for filling voids and forming claddings.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional weld filler application processes are used to repair complex components, then repair capability is provided, but manufacturing precision and effectiveness are insufficient
Solution Approach 1:
The system performs preliminary scanning and measurement of the component to be repaired, creating a digital model before the repair process begins. This allows the additive manufacturing toolpath to be precisely tailored to the actual component geometry, ensuring high repair precision while maintaining ease of manufacture through automated processes.
Solution Approach 2:
The system compares predicted characteristics of the repaired component against reference data from the digital model, providing feedback to adjust the machining toolpath. This closed-loop control ensures that repair precision is achieved while the automated feedback mechanism maintains ease of manufacture by reducing manual intervention.
2Reliability
If additive manufacturing is used to deposit powder and repair components, then repair effectiveness is improved, but machining precision for final dimensions becomes challenging
Solution Approach 1:
The system generates a predicted model of the additive manufacturing process outcomes before actual deposition. This preliminary action allows the machining toolpath to be pre-planned to compensate for expected variations, ensuring dimensional accuracy while maintaining component reliability through the additive repair process.
Solution Approach 2:
The system compares predicted characteristics after additive manufacturing against reference data, providing feedback to optimize the machining process. This ensures that final dimensional accuracy is achieved while the component's reliability is maintained through the combination of additive repair and precision machining.
3Manufacturing precision
If comprehensive scanning and prediction processes are implemented, then manufacturing precision is improved, but process time and complexity increase
Solution Approach 1:
The system performs scanning and creates digital models before the repair process, and generates predicted characteristics before machining. This preliminary action consolidates measurement and prediction activities upfront, allowing for optimized toolpath planning that improves precision while reducing overall process cycle time by avoiding iterative adjustments during manufacturing.
4Reliability
If material is deposited to fill voids and form claddings, then component condition is improved, but material waste increases
Solution Approach 1:
The system scans the component and identifies specific defect locations and dimensions before material deposition. The additive manufacturing toolpath is precisely tailored to deposit material only where needed to fill voids and form claddings, improving component condition while minimizing material waste through targeted deposition rather than blanket application.
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 approach enables accurate repair and manufacturing of complex components by filling voids and restoring dimensions, improving the component's condition to match design specifications, reducing material waste and enhancing the component's performance.
Implementation Method 1
an additive manufacturing device melting the powder
Implementation Method 2
scanning a component using structured light to provide scanned data
Data Source
Figure 1A~1C
Figure 2A
Figure 2B
AI summary
A method of manufacturing a component (20) includes a) depositing powder (40A, 40B) using an additive manufacturing device (24) based upon additive manufacturing data to provide a first object, the additive manufacturing device (24) melting the powder (40A, 40B), b) determining predicted characteristics of the first object based upon the additive manufacturing data developed in step a), c) comparing the predicted characteristics of the first object to the reference data to provide machining data and d) machining the first object using the machining data. A system for manufacturing a component (20) is also disclosed.