Structured Light Component Overhaul With Additive Repair Machining
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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 applies parameter changes by transitioning from traditional manual braze and weld filler application to a controlled additive manufacturing process using direct laser braze cladding. This changes the deposition parameters (material feed rate, laser power, scanning speed) to achieve precise material placement with high efficiency, resolving the contradiction between repair precision and repair efficiency
Solution Approach 2:
The patent replaces the mechanical manual application process with an automated system that integrates structured light scanning, additive manufacturing, and machining. This substitution of mechanical processes with automated systems simultaneously improves both precision (through computer-controlled deposition) and efficiency (through automated multi-step processing), directly addressing the technical contradiction
2Manufacturing precision
If additive manufacturing is used to deposit material, then material can be precisely placed, but additional machining is required to achieve final dimensions
Solution Approach 1:
The patent merges multiple processes (additive manufacturing, machining, and measurement) into a single integrated system. The additive manufacturing device deposits material with high precision, and the same system performs machining and structured light scanning to verify dimensions. This merging reduces overall process complexity despite the added capability, while maintaining high material placement precision
Solution Approach 2:
The patent implements feedback by using structured light scanning to measure the deposited material and comparing actual dimensions to target dimensions. This feedback loop allows the system to adjust subsequent deposition or machining operations to achieve final target dimensions, resolving the contradiction by using precision deposition followed by corrective machining based on measured feedback
3Adaptability or versatility
If two types of braze powders are used for different repair needs, then both void filling and dimensional repair can be achieved, but process complexity increases
Solution Approach 1:
The patent applies universality by designing the additive manufacturing device to handle multiple types of braze powder (e.g., void-filling powder and dimensional repair powder) through a single system. The device can switch between different materials based on the repair requirements, providing versatile repair capabilities without requiring separate equipment for each material type, thus increasing adaptability while managing complexity
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 enables precise repair of complex components by accurately filling voids and restoring surface dimensions, improving the component's performance and extending its lifespan without the need for complete replacement.
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
depositing material on the component using an additive manufacturing device
Implementation Method 4
machining the first object using the machining data
Data Source
AI summary
A method of overhaul of a component includes a) scanning a component using structured light to provide scanned data, b) comparing the scanned data to reference data to provide additive manufacturing data, c) depositing material on the component using an additive manufacturing device 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 of step a), e) comparing the predicted characteristics of the first object to the reference data to provide machining data and f) machining 416 the first object using the machining data.