Gas Turbine Component Stress Region Verification

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Solution Overview

Problem

Current methods for predicting and verifying elevated stress regions in gas turbine engine components are inaccurate due to deviations between simulation and actual conditions, leading to unreliable stress application during repair processes, which may cause cracking.

Innovation Solution

Applying a controlled stress to a gas turbine engine component to induce surface cracking, allowing the identification of actual elevated stress regions and verifying predicted locations through comparison with the actual cracking patterns, thereby determining a safe maximum stress for repair processes.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Loss of time

If computer analysis is used to predict the location of the highest stress region, then the number of sections required for metallurgical analysis is reduced, but the accuracy of predicting the location of the highest stress region deteriorates due to deviations from actual conditions

Engineering Contradiction:

Improvetime for metallurgical analysisVSAvoidaccuracy of predicted location of highest stress region

Core Design Contradiction:

Loss of timeVSMeasurement precision

Solution Approach 1:

The patent applies preliminary action by using computer analysis to predict the location of the highest stress region before conducting metallurgical analysis. This allows the component to be sectioned only at the predicted high-stress location, reducing the number of sections needed and saving time. The computer analysis serves as a preliminary step that guides subsequent targeted analysis.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The patent implements feedback by comparing the predicted location of the highest stress region from computer analysis with the actual location determined through metallurgical analysis of sectioned components. This feedback loop allows for verification and refinement of the computer analysis model, improving its accuracy over time while maintaining the time-saving benefits of targeted sectioning.

Inventive Principle:

Principle #23Feedback

2Productivity

If stress is applied during the repair process based on computer analysis predictions, then the repair efficiency is improved, but the reliability of avoiding cracking deteriorates due to inaccurate stress predictions

Engineering Contradiction:

Improverepair process efficiencyVSAvoidreliability of stress application to avoid cracking

Core Design Contradiction:

ProductivityVSReliability

Solution Approach 1:

The patent uses computer analysis to preliminarily determine the maximum stress that can be applied during the repair process without causing cracking. This preliminary determination allows for efficient repair planning and execution, as the stress parameters are pre-calculated based on the component's geometry and material properties.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The patent applies feedback by using results from metallurgical analysis of representative components to verify and refine the computer analysis predictions of maximum stress. This feedback ensures that the stress parameters used in actual repair processes are reliable and based on both simulation and experimental validation, preventing cracking while maintaining repair efficiency.

Inventive Principle:

Principle #23Feedback

3Measurement precision

If representative components are sectioned into a large number of pieces for metallurgical analysis, then the accuracy of detecting cracking is improved, but the complexity and time required for analysis increases

Engineering Contradiction:

Improveaccuracy of detecting crackingVSAvoidcomplexity of sectioning and analysis process

Core Design Contradiction:

Measurement precisionVSDevice complexity

Solution Approach 1:

The patent applies segmentation by dividing the component into sections based on predicted stress regions. Instead of uniformly sectioning the entire component, only the high-stress regions identified through computer analysis are sectioned for metallurgical examination. This targeted segmentation reduces the number of pieces to be analyzed while maintaining detection accuracy.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The patent implements local quality by concentrating metallurgical analysis resources on specific high-stress regions rather than applying uniform analysis throughout the entire component. The computer analysis identifies locations with different stress characteristics, allowing for localized detailed examination where it is most needed, thereby reducing overall analysis complexity while maintaining high detection accuracy.

Inventive Principle:

Principle #3Local quality

Data Source

PatentUS8291589B2Method for establishing a location of an elevated stress region

Publication Date: 2012.10.23 RTX CORP

AI summary

A method for use in repairing gas turbine engine components includes applying a stress to a first gas turbine engine component to cause surface cracking on the first gas turbine engine component and establishing a location of an elevated stress region of a second gas turbine engine component based upon the location of the surface cracking on the first gas turbine engine component.