Stator Vane Edge Repair Using Directed Energy Deposition
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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 utilizing directed energy deposition (DED) additive manufacturing for localized repairs, which applies minimal heat and automates the process by analyzing defects with heat maps, removing standardized portions to form scallops, and rebuilding edges to their original shape, followed by blending to smooth the stator vanes.
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 patent changes the fundamental parameters of the repair process by transitioning from manual TIG welding to automated directed energy deposition (DED) additive manufacturing. This parameter change enables precise control of heat input, build rate, and material deposition, thereby achieving defect repair while minimizing thermal distortion of the component geometry.
Solution Approach 2:
The patent replaces the manual mechanical welding process with an automated additive manufacturing system. The DED process uses a robotic or automated system to deposit material layer-by-layer, substituting the manual dexterity-based TIG process with a controlled, programmable system that maintains consistent thermal conditions and reduces operator-induced variability.
2Reliability
If manual TIG weld process is used for defect removal and repair, then defects can be addressed, but the process is time and labor intensive
Solution Approach 1:
The patent implements self-service through automated defect detection and repair systems. The integrated inspection system automatically identifies defects, and the DED system automatically executes the repair process without continuous manual intervention. This automation eliminates the need for skilled welders to perform each repair manually, significantly improving productivity while maintaining repair quality.
Solution Approach 2:
The patent enables continuous repair operations through automated DED processes that can operate continuously without the interruptions inherent in manual welding. The automated system maintains consistent deposition rates and can repair multiple defects in sequence without the setup time and labor coordination required for manual processes, thereby improving overall repair efficiency.
3Manufacturing precision
If standardized portion removal is performed to form scallops, then the removed portion conforms to theoretical model plus tolerances, but additional processing steps are required
Solution Approach 1:
The patent applies preliminary action by pre-defining the scallop geometry and removal parameters based on theoretical models and tolerance requirements before the actual repair process. The standardized scallop design allows for pre-programmed toolpaths and material deposition patterns, ensuring that the removed portions conform to specifications while reducing the complexity of real-time decision-making during repair operations.
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 processing time, heat input, and distortion, enabling efficient and precise repair of turbine engine stator stages with minimal human error and optimized engineering requirements.
Implementation Method 1
repairing the first stator vane including filling the first scallop to fill the first stator vane to its original size and shape creating a repaired portion
Data Source
AI summary
A method of 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 based on the analysis that there is a first defect on an edge of a first stator vane of the plurality of stator vanes, removing a portion of the first stator vane including the first defect to form a first scallop on the edge of the first stator vane, repairing the first stator vane including filling the first scallop to fill the first stator vane to its original size and shape creating a repaired portion, and performing a blending process to the stator stage including the first stator vane and the repaired portion to smooth the plurality of stator vanes.