Stator Vane Edge Repair Using DED to Reduce Weld Distortion

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Solution Overview

Problem

Turbine engine components often require labor-intensive manual TIG weld processes for defect repair, leading to excessive distortion due to heat input, which are inefficient and time-consuming.

Innovation Solution

Utilizing directed energy deposition (DED) as an additive manufacturing technique for localized repairs, minimizing heat input and enabling standardized, automated defect removal and rebuilding processes.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of repair

If manual TIG weld process is used for defect repair, then repair can be performed on turbine engine components, but excessive distortion occurs due to heat input and the process is time and labor intensive

Engineering Contradiction:

Improverepair capabilityVSAvoidcomponent distortion

Core Design Contradiction:

Ease of repairVSManufacturing precision

Solution Approach 1:

The patent changes the fundamental parameters of the repair process by transitioning from manual TIG welding to automated directed energy deposition (DED). This involves changing the heat source characteristics, deposition method, and process control parameters to achieve precise material placement with minimal thermal distortion while maintaining repair capability on turbine engine components

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent replaces the manual mechanical TIG welding process with an automated DED system that uses computer-controlled positioning and automated wire feeding. This substitution eliminates manual operation variability and enables precise control of the deposition process, reducing heat input and distortion while maintaining repair functionality

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Ease of repair

If manual TIG weld process is used for defect repair, then repair can be performed, but the process is time and labor intensive

Engineering Contradiction:

Improverepair capabilityVSAvoidrepair efficiency

Core Design Contradiction:

Ease of repairVSProductivity

Solution Approach 1:

The patent replaces manual TIG welding operations with an automated directed energy deposition system featuring computer-controlled positioning, automated wire feeding, and programmable motion paths. This automation eliminates manual labor requirements and significantly increases repair throughput and consistency

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent implements continuous automated deposition processes where the DED system can operate without interruption, maintaining consistent material deposition rates. The automated system allows for continuous processing of multiple defects or multiple components, significantly improving overall productivity compared to manual intermittent welding operations

Inventive Principle:

Principle #20Continuity of useful action

3Productivity

If standardized repair processes are implemented, then productivity and consistency are improved, but adaptability to various defect types may be reduced

Engineering Contradiction:

Improverepair throughputVSAvoiddefect type flexibility

Core Design Contradiction:

ProductivityVSAdaptability or versatility

Solution Approach 1:

The patent implements a dynamic repair system where the DED process parameters (wire feed rate, deposition speed, laser power, positioning) can be adjusted in real-time based on defect characteristics. The system maintains standardized automated operations for common defect types while allowing flexible parameter modification to accommodate varying defect sizes, locations, and geometries on turbine engine components

Inventive Principle:

Principle #15Dynamics

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

The DED process reduces distortion and processing time, allowing for efficient, standardized, and less labor-intensive repairs of turbine engine components, optimizing metallurgical, structural, and aerodynamic impacts.

Implementation Method 1

repairing the edge of the first stator vane using an additive manufacturing process, including filling the first scallop to rebuild the edge of the first stator vane

Methodology Applied

Scientific EffectDirected Energy Deposition: Laser Beam Welding

Implementation Method 2

The DED process reduces distortion and processing time

Methodology Applied

Scientific EffectMelting: Melting

Data Source

PatentEP4491849B1Localized rework using directed energy deposition

Publication Date: 2026.04.15 RTX CORP

Figure 1A
Figure 1B
Figure 2~3

AI summary

A method of repairing a stator stage (200) is disclosed herein. The method includes receiving a stator stage (200) including a plurality of stator vanes (406) disposed between an outer diameter (402) and an inner diameter (404), analyzing the stator stage (200) for defects, determining based on the analysis that there is a first defect (412a) on an edge of a first stator vane (406a) of the plurality of stator vanes (406), removing a portion of the first stator vane (406a; 506) including the first defect (412a) to form a first scallop (422a) on the edge of the first stator vane (406a , repairing the first stator vane (406a) including filling the first scallop (422a) to fill the first stator vane (406a) to its original size and shape creating a repaired portion (432a), and performing a blending process to the stator stage (200) including the first stator vane (406a) and the repaired portion (432a) to smooth the plurality of stator vanes (406).