In Situ Repair of Gas Turbine Casing Abradable Coatings
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Solution Overview
Problem
Conventional methods for repairing abradable materials in gas turbine engine casings are time-consuming and expensive, requiring full strip and recoating, which is not efficient for in-situ repairs.
Innovation Solution
A system and method using an articulating guide with a repair tool having a shaped distal end to trench out defects in abradable materials, assisted by heating and ultrasonic vibration, and filling the trenches with a filler material through an access port, allowing for localized and efficient in-situ repairs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If full strip and recoating of abradable material is performed, then complete repair coverage is achieved, but service time and cost increase significantly
Solution Approach 1:
The invention applies local quality by transitioning from global recoating to localized repair. The articulating guide with repair tools enables targeted intervention at specific defect locations on the abradable material, applying filler material only where needed rather than stripping and recoating the entire surface. This localized approach maintains repair effectiveness while dramatically reducing service time.
Solution Approach 2:
The invention segments the repair process into discrete, localized operations. The articulating guide divides the repair task into individual defect treatments, allowing each defect to be addressed separately with specific tools (trenching tool, filling tool). This segmentation enables parallel processing of multiple defects and eliminates the need for complete strip and recoat operations.
2Reliability
If full strip and recoating of abradable material is performed, then complete repair coverage is achieved, but repair cost increases
Solution Approach 1:
The invention reduces repair cost by applying material only where defects exist. The articulating guide system with targeted filling tools delivers filler material precisely to defect locations, eliminating the waste associated with complete strip and recoat operations. This localized material application significantly reduces both material consumption and labor costs while maintaining repair effectiveness.
Solution Approach 2:
The invention applies partial action by performing repair only to the extent necessary - addressing only defective areas rather than the entire abradable surface. The articulating guide enables selective treatment of spalled or eroded regions, applying filler material in proportion to the actual damage rather than uniformly across the entire component, thereby reducing overall repair cost.
3Reliability
If conventional repair methods are used, then thorough repair is achieved, but operational downtime increases
Solution Approach 1:
The articulating guide system enables quick assessment and repair of localized defects without requiring complete disassembly or shutdown of the gas turbine engine. By targeting only affected areas with specific repair tools, the system maintains high repair quality while minimizing operational downtime and improving overall productivity.
Solution Approach 2:
The articulating guide with integrated inspection and repair tools enables preliminary assessment of abradable material conditions followed by immediate localized repair. This preliminary action approach allows defects to be identified and corrected during scheduled maintenance intervals without requiring extended shutdowns, thereby improving operational efficiency.
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 reduces service time and cost by enabling easy and efficient in-situ repairs of turbine blades, making the process simpler and more cost-effective compared to traditional methods.
Implementation Method 1
The heating element is configured to heat the abradable material
Implementation Method 2
the repair tool having a shaped distal end to trench out defects in abradable materials, assisted by heating and ultrasonic vibration
Data Source
AI summary
The present disclosure is directed to a system and method for repairing an abradable material coated on a casing of a gas turbine engine. The system includes an articulating guide configured to fit into an access port of the gas turbine engine. Further, the articulating guide has a proximal end and a distal end. The system also includes a repair tool configured at a distal end of the articulating guide. The repair tool includes a body having a proximal end and a shaped distal end, with the shaped distal end extending away from the body. Thus, the shaped distal body is configured to trench out an area of the abradable material comprising a defect. The system also includes a filler material for filling the trenched out area.