Structured Light Braze Repair Machining With Diffusion Bonding
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Solution Overview
Problem
Existing manufacturing processes for components using braze or weld filler material result in material waste and secondary defects, necessitating a need for improved methods that reduce waste and defects.
Innovation Solution
A method involving additive deposition of braze powder, sintering, and diffusion bonding with structured light scanning and machining to create a component, utilizing a system comprising a scanning device, additive manufacturing device, furnace, and machining device to enhance precision and reduce defects.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional braze or weld filler material processes are used, then component defects can be repaired, but material waste and secondary defects increase
Solution Approach 1:
The patent changes the temperature parameter by using low-temperature sintering (below the melting point of the substrate material) instead of traditional high-temperature welding or brazing processes. This parameter change allows the filler material to be deposited and bonded without causing thermal damage or excessive material waste, directly resolving the contradiction between repair reliability and material loss
Solution Approach 2:
The patent replaces traditional mechanical welding or brazing processes with an additive manufacturing system that uses controlled material deposition and sintering. This substitution enables precise material placement, reducing material waste while maintaining repair quality, and eliminates the harmful thermal effects associated with conventional joining processes
2Reliability
If traditional braze or weld filler material processes are used, then component defects can be repaired, but secondary process-related defects form in the substrate
Solution Approach 1:
The patent changes the temperature parameter by using low-temperature sintering (below the melting point of the substrate material) instead of traditional high-temperature welding or brazing processes. This parameter change allows the filler material to be deposited and bonded without causing thermal damage or excessive material waste, directly resolving the contradiction between repair reliability and material loss
Solution Approach 2:
The patent replaces traditional mechanical welding or brazing processes with an additive manufacturing system that uses controlled material deposition and sintering. This substitution enables precise material placement, reducing material waste while maintaining repair quality, and eliminates the harmful thermal effects associated with conventional joining processes
3Loss of substance
If additive manufacturing with sintering and diffusion bonding is used, then material waste and secondary defects are reduced, but process complexity increases
Solution Approach 1:
The patent merges multiple functions into a single additive manufacturing system: material deposition, sintering, and diffusion bonding are all performed in one integrated process. This consolidation reduces the need for separate equipment and operations, thereby managing process complexity while achieving material waste reduction through precise controlled deposition
Solution Approach 2:
The patent replaces traditional mechanical welding or brazing processes with an additive manufacturing system that uses controlled material deposition and sintering. This substitution enables precise material placement, reducing material waste while maintaining repair quality, and eliminates the harmful thermal effects associated with conventional joining processes
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 method reduces material waste and secondary defects by using low-temperature sintering and diffusion bonding, resulting in a component with improved accuracy and reduced post-processing requirements.
Implementation Method 1
A first object is scanned using structured light to provide first object scan data
Implementation Method 2
The braze powder is sintered using a laser of the additive manufacturing device 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 sintered braze material is heated to melt the sintered braze material and to diffusion bond the sintered braze material to the substrate
Data Source
AI summary
A method is disclosed for providing a component. During this method, braze powder is additively deposited with a substrate. 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 to provide braze filler material. A first object is scanned using structured light to provide first object scan data. The first object includes the substrate and the braze filler material diffusion bonded to the substrate. The first object scan data is compared to first object reference data to provide machining data. The first object is machined using the machining data to provide a second object.