Gas Turbine Shroud Tile Repair via Side Rail Brazing
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Solution Overview
Problem
Conventional methods for repairing shroud tiles in gas turbines are time-consuming and costly due to the need for welding or brazing, which requires positioning the tiles upright and machining, making it inefficient to repair both sides simultaneously.
Innovation Solution
A method involving the removal of damaged portions from the shroud tile sides and securing replacement side rails, utilizing a fixture assembly that applies compressive force during brazing to ensure dimensional accuracy without additional machining, allowing for simultaneous repair of both sides.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional welding and brazing processes are used to build up damaged side surfaces, then the shroud tile can be repaired, but the repair process becomes very time and labor intensive
Solution Approach 1:
The method removes damaged portions and prepares the surface in advance before applying new material. By preparing the substrate beforehand with proper geometry and cleanliness, the subsequent brazing process is significantly accelerated, reducing overall repair time while maintaining reliability
Solution Approach 2:
The invention replaces the traditional multi-step mechanical process (welding, building up material, grinding, machining) with a more efficient process that uses controlled material application and selective brazing, eliminating the need for extensive post-processing mechanical operations
2Manufacturing precision
If shroud tiles are positioned upright for material buildup during repair, then proper material application is achieved, but only one side can be repaired at a time
Solution Approach 1:
The method transitions from vertical upright positioning to horizontal positioning of the shroud tile. This dimensional change allows access to both sides of the tile simultaneously, enabling parallel repair operations while maintaining precise material application through controlled placement and brazing procedures
3Reliability
If extensive braze and weld material is used to build up side surfaces, then damaged areas are restored, but the shroud tile must be positioned upright limiting repair capacity
Solution Approach 1:
The method extracts and removes only the damaged portions of the shroud tile sides rather than building up material over the entire surface. This selective removal approach reduces the volume of material needed for restoration and simplifies the overall repair process by targeting only the affected areas
Solution Approach 2:
The repair process applies material and brazing operations locally to the damaged areas rather than uniformly across the entire side surface. This localized approach restores the necessary structural integrity while minimizing material usage and process complexity
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 quick, efficient, and cost-effective repair of shroud tiles by maintaining dimensional tolerances and reducing labor and manufacturing costs, while ensuring proper braze joint formation and oxidation resistance.
Implementation Method 1
utilizing a fixture assembly that applies compressive force during brazing to ensure dimensional accuracy
Implementation Method 2
securing at least one side rail to the shroud tile in place of the removed portion
Data Source
AI summary
A method for repairing a shroud tile of a gas turbine is disclosed. The method may generally include removing a portion of the shroud tile along at least one of a first side and a second side of the shroud tile and securing at least one side rail to the shroud tile in place of the removed portion of the shroud tile.