Stator Stage Segment Replacement to Minimize Repair Distortion
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Turbine engine components often suffer from defects or damage during production or service use, requiring labor-intensive manual TIG weld repairs that result in excessive distortion due to heat input.
Innovation Solution
A method involving defect analysis, segment removal, and additive manufacturing using powder bed fusion to create matching segments for repair, which are then attached and blended to maintain component shape and functionality.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If manual TIG weld process is used to repair defects, then defects can be removed and repaired, but excessive distortion occurs due to heat input
Solution Approach 1:
The component is divided into modular segments that can be independently removed and replaced. Instead of welding the entire component, only the defective segment is segmented out and a new healthy segment is attached in its place, avoiding heat input to the majority of the component and preventing excessive distortion.
Solution Approach 2:
The defective segment is extracted from the component entirely, removing the source of distortion. By taking out only the problematic portion rather than applying heat across the entire component, the method eliminates the cause of excessive distortion while maintaining repair effectiveness.
2Reliability
If manual TIG weld process is used for defect repair, then defects can be addressed, but the process is time and labor intensive
Solution Approach 1:
By segmenting the repair process into standardized module removal and attachment operations, the method enables more efficient workflows compared to manual welding. The modular approach allows for pre-prepared replacement segments and reduces the skill-intensive nature of manual welding, thereby improving productivity.
Solution Approach 2:
The manual welding process is replaced with a mechanical attachment process. Instead of using heat and manual dexterity for welding, the repair uses mechanical attachment methods to join segments, which is faster, more consistent, and less labor-intensive, thereby significantly improving repair efficiency.
3Productivity
If segment removal and additive manufacturing is used for repair, then heat input and processing time are reduced, but new manufacturing processes are required
Solution Approach 1:
Healthy segments are pre-manufactured using additive manufacturing processes before the repair is needed. This preliminary action allows the actual repair to be a simple attachment operation rather than a complex manufacturing process, reducing on-site complexity while maintaining high productivity benefits.
Solution Approach 2:
The manufacturing approach transitions from traditional subtractive methods to additive manufacturing, changing the fundamental production parameters. This enables complex segment geometries to be created efficiently and allows for precise control of segment properties, facilitating the modular repair approach while managing overall system 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 approach reduces heat input and processing time, minimizes distortion, and enables efficient, automated repair of turbine engine stator stages with reduced labor and time, while maintaining structural and aerodynamic integrity.
Implementation Method 1
manufacturing the second segment includes using an additive manufacturing process. In various embodiments, the additive manufacturing process is a powder bed fusion process
Implementation Method 2
the additive manufacturing process is a powder bed fusion process
Data Source
AI summary
A method for repairing a stator stage is disclosed herein. The method includes receiving a stator stage including a plurality of stator vanes disposed between an outer diameter and an inner diameter, analyzing the stator stage for defects, determining there is a first defect in a first segment of a the stator stage, the first segment including at least one of a first portion of the outer diameter, a first portion of the inner diameter, or a first stator vane, removing the first segment from the stator stage forming a void in the stator stage, manufacturing a second segment that is the same size as the first segment, attaching the second segment to the stator stage to fill the void, performing a blending process on the stator stage including the second segment to smooth the plurality of stator vanes including the second stator vane.