Thermal Rework Press Assembly for Precise Distortion Correction
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Solution Overview
Problem
Existing rework processes for components with high strength and low ductility properties, such as superalloys, often introduce residual stresses and degrade mechanical properties, limiting the effectiveness of dimensional correction and introducing inaccuracies.
Innovation Solution
A rework press assembly with a die and ram that undergo differential thermal expansion, allowing for precise correction of dimensional distortions by increasing the ram's length at elevated temperatures to compress the component, while inhibiting residual stress introduction.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional rework processes (hot spotting, brazing, machining) are used on high strength and low ductility components, then dimensional distortions can be corrected, but residual stresses are introduced and mechanical properties are degraded
Solution Approach 1:
The patent applies parameter changes by heating the component to elevated temperatures during the rework process. This temperature parameter change modifies the material properties, allowing dimensional correction through thermal expansion and controlled cooling, which reduces residual stress introduction and maintains mechanical property integrity in high strength, low ductility materials
Solution Approach 2:
The patent employs preliminary action by pre-heating the component before applying corrective forces. This preliminary thermal treatment prepares the material by reducing its yield strength and increasing ductility, enabling more effective dimensional correction without introducing excessive residual stresses that would compromise mechanical properties
2Manufacturing precision
If hot spotting process is used on low strength and high ductility materials, then dimensional distortions can be corrected, but residual stresses remain in the heated area
Solution Approach 1:
The patent applies preliminary heating to the entire component or affected areas before corrective forcing. This preliminary thermal treatment uniformly raises the material temperature, reducing yield strength and enabling more uniform plastic deformation that distributes residual stresses more evenly rather than concentrating them in localized heated zones
Solution Approach 2:
The patent employs periodic thermal cycles involving heating to elevated temperatures followed by controlled cooling. This periodic thermal action allows repeated cycles of softening and hardening, enabling progressive dimensional correction while distributing residual stresses through multiple controlled thermal-mechanical cycles rather than introducing them in a single concentrated event
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
Enables accurate and controlled correction of dimensional distortions in high-strength, low-ductility components without degrading mechanical properties, improving upon traditional methods by reducing residual stress and enhancing precision.
Implementation Method 1
At least one of the die and the ram has a first length, relative to the axis, in response to the rework press assembly being at a first thermal condition. The at least one of the die and the ram has a second length, relative to the axis, in response to the press being at a second thermal condition, and the second length is greater than the first length.
Data Source
AI summary
A rework press assembly for reworking a dimensionally non-conformant component is provided. The rework press assembly includes a frame, a die coupled to the frame and configured to contact a first portion of the component, and a ram. The ram is coupled to the frame opposite the die with respect to an axis of the rework press assembly and is configured to contact a second portion of the component. The ram and the die define a component cavity therebetween. At least one of the die and the ram has a first length, relative to the axis, in response to the rework press assembly being at a first thermal condition. The at least one of the die and the ram has a second length, relative to the axis, in response to the rework press assembly being at a second thermal condition, and the second length is greater than the first length.