Structured Light Overhaul of Worn Components With Adaptive Repair
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Solution Overview
Problem
Complex components, such as those in gas turbine engines, require effective repair methods to extend their lifespan rather than replacement, as existing braze and weld filler application processes are not fully optimized for precision and efficiency.
Innovation Solution
A method involving structured light scanning to generate additive manufacturing toolpaths, followed by material deposition using a direct laser braze cladding machine, and subsequent machining to restore the component to its original specifications, utilizing two types of braze powders with different properties for filling defects and dimensional repair.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional braze and weld filler application processes are used, then repair can be performed on complex components, but precision and efficiency are not optimized
Solution Approach 1:
The patent combines multiple repair processes (scanning, additive manufacturing, machining) into an integrated adaptive overhaul system that operates in a single fixture, eliminating repositioning and setup time while maintaining precision throughout the repair process
Solution Approach 2:
The system dynamically adjusts process parameters based on actual component geometry measured during scanning, adapting the additive manufacturing and machining operations to the specific defects and wear patterns found on each component
2Ease of manufacture
If complex components are repaired instead of replaced, then cost is reduced, but repair process complexity increases
Solution Approach 1:
The component itself provides the repair template through its scanned geometry, where the measured actual geometry automatically generates the toolpaths for both additive manufacturing and machining operations, eliminating the need for complex external programming and setup
Solution Approach 2:
The component is scanned and its actual geometry is captured before repair begins, allowing the system to pre-calculate the exact material deposition and removal requirements based on the specific defects present, rather than using generic repair procedures
3Manufacturing precision
If additive manufacturing is used to deposit material, then defects and wear can be filled, but over-deposition requires subsequent machining
Solution Approach 1:
The system uses feedback from the scanned component geometry to precisely control the additive manufacturing process, calculating the exact amount of material needed to fill defects and wear, thereby minimizing over-deposition and reducing subsequent machining requirements
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 allows for precise repair of complex components by accurately depositing and removing material, effectively addressing defects and wear, thereby extending the component's lifespan and maintaining performance.
Implementation Method 1
scanning a component using structured light to provide scanned data
Implementation Method 2
depositing material on the component using an additive manufacturing device based upon the additive manufacturing data
Implementation Method 3
machining the first object using the machining data
Data Source
Figure 1A~1B
Figure 2A~2B
Figure 2C
AI summary
A method of overhaul of a component (20) includes a) scanning a component (20) using structured light (103) to provide scanned data (106), b) comparing the scanned data (106) to reference data to provide additive manufacturing data, c) depositing material (62A) on the component (20) using an additive manufacturing device (24) 24 based upon the additive manufacturing data to provide a first object, d) determining predicted characteristics of the first object based upon the additive manufacturing data developed in step b) and the scanned data (106) of step a), e) comparing the predicted characteristics of the first object to the reference data to provide machining data and f) machining the first object using the machining data.