Structured Light Braze Deposition for Low-Stress Component Repair
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Solution Overview
Problem
Existing manufacturing processes for components face challenges in reducing material waste and minimizing secondary defects, such as thermally induced stresses and distortion, particularly in additive manufacturing techniques like laser deposition welding.
Innovation Solution
The method involves scanning a substrate using structured light to generate additive manufacturing data, depositing braze powder, sintering it with a laser, and diffusion bonding the sintered braze material to the substrate, which reduces material waste and secondary defects by using lower processing temperatures and minimizing internal stresses.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional laser deposition welding is used to apply filler material, then the component can be repaired or manufactured, but thermally induced stresses and distortion occur as secondary defects
Solution Approach 1:
The patent changes the temperature parameter by using braze filler material with a lower melting point than the substrate material. This allows the processing temperature to be reduced below the substrate's melting point, preventing thermally induced stresses and distortion while still achieving reliable bonding through diffusion bonding at the reduced temperature
Solution Approach 2:
The patent utilizes phase transitions of the braze filler material (melting and solidification) at a lower temperature range than the substrate material. The filler material melts to form a bonding layer and then solidifies to create the joint, enabling repair without subjecting the substrate to damaging high temperatures that would cause distortion
2Quantity of substance
If conventional braze filler application processes are used, then material can be applied to the substrate, but material waste occurs
Solution Approach 1:
The patent applies preliminary action by first depositing a slurry containing filler material onto the substrate before the actual bonding process. This preliminary deposition ensures precise placement of the filler material exactly where needed, preventing excess material application and subsequent waste while preparing the substrate for controlled diffusion bonding
Solution Approach 2:
The patent applies local quality by using selective area deposition where filler material is applied only to specific regions of the substrate that require repair or bonding. This localized approach prevents unnecessary material application in areas that don't need treatment, reducing overall material waste while maintaining effective repair quality
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 effectively reduces material waste and secondary defects, minimizes thermally induced stresses and distortion, and requires less post-processing compared to traditional methods, while improving the accuracy and efficiency of component repair and formation.
Implementation Method 1
a substrate is scanned using structured light to provide substrate scan data indicative of one or more characteristics of the substrate
Implementation Method 2
The braze powder is sintered together using a laser beam during the depositing of the braze powder
Implementation Method 3
The braze powder is sintered together during the depositing of the braze powder to provide the substrate with sintered braze material
Implementation Method 4
The furnace is configured to receive the substrate and melt the sintered braze material to facilitate diffusion bonding of the sintered braze material to the substrate
Data Source
AI summary
A method is disclosed for providing a component. During this method, a substrate is scanned using structured light to provide substrate scan data. The substrate scan data is compared to substrate reference data to provide additive manufacturing data. Braze powder is deposited with the substrate based on the additive manufacturing data. The braze powder is sintered together during the depositing of the braze powder to provide the substrate with sintered braze material. The sintered braze material is heated to melt the sintered braze material and to diffusion bond the sintered braze material to the substrate.