Gas Turbine Vane Repair Using Salvaged Cooling Baffles
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Solution Overview
Problem
Gas turbine engine vane segments often require costly repairs or replacements due to wear and damage, with existing methods being inefficient and costly, especially when dealing with cooling baffles that are metallurgically bonded and lack serial number traceability.
Innovation Solution
A method involving the removal and salvage of engine-run cooling baffles from damaged vane segments, followed by their attachment to newly fabricated non-engine-run manufacturing details, with additional operations like brazing, machining, and coating, and marking for serial number traceability, to create a cost-effective repair while maintaining part serial number traceability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If cooling baffles are metallurgically bonded to airfoils, then the structural integrity and cooling function are improved, but the cost of repair increases and serial number traceability is lost
Solution Approach 1:
The vane segment is divided into separable components: the airfoil assembly and the cooling baffle. The cooling baffle is designed to be removable from the airfoil, allowing the airfoil to be reused as a salvageable component while replacing only the damaged baffle. This segmentation enables cost-effective repair by preserving valuable airfoil material.
Solution Approach 2:
The method recovers and reuses the airfoil component after removing the damaged cooling baffle. The airfoil is inspected, cleaned, and prepared for reuse by attaching a new or refurbished cooling baffle. This recovery process eliminates the need to discard and replace the entire vane segment, reducing repair costs.
2Reliability
If the entire vane segment is replaced, then reliability is improved, but cost and waste increase
Solution Approach 1:
The vane segment is segmented into replaceable and salvageable parts. Only the damaged cooling baffle is replaced while the airfoil is retained and reused. This selective replacement minimizes material waste while ensuring the repaired component meets reliability requirements.
Solution Approach 2:
The airfoil is recovered and reused after removing the damaged cooling baffle. The process inspects and prepares the airfoil for reuse, preventing it from being discarded with the damaged baffle. This recovery approach reduces material waste and associated costs.
3Ease of manufacture
If cooling baffles are removed and reused, then repair cost decreases, but serial number traceability is lost
Solution Approach 1:
The serial number information from the original vane segment is copied and transferred to the repaired component. After assembling the airfoil with the reused or new cooling baffle, the serial number is reapplied to the repaired vane segment, maintaining traceability throughout the component's service life.
Solution Approach 2:
The serial number is transferred or reapplied to the repaired vane segment as a preliminary step before returning the component to service. This ensures traceability is established before the component enters its next operational cycle, preventing information loss.
4Strength
If cooling baffles are metallurgically bonded, then structural integrity is improved, but ease of repair worsens
Solution Approach 1:
The cooling baffle and airfoil are designed as segmented components that can be separated. The connection method allows for controlled separation during repair while maintaining structural integrity during operation. This segmentation enables straightforward removal and replacement of baffles without damaging the airfoil.
Solution Approach 2:
The connection between the cooling baffle and airfoil is designed to be dynamic in nature - strongly bonded during operation for structural integrity, but capable of controlled separation during repair. The bonding method allows for reversible attachment that maintains strength when assembled but facilitates removal when needed.
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 method reduces repair costs by utilizing salvaged baffles and newly fabricated components, maintaining serial number traceability, and adhering to regulatory requirements, thus providing a cost-effective solution for vane segment repairs while ensuring part integrity and traceability.
Implementation Method 1
These vane segments can also include cooling features, such as film cooling openings and cooling baffles that extend into the airfoils
Implementation Method 2
The cooling baffles are metallurgically bonded to the airfoils
Data Source
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AI summary
A method of repairing a vane segment (20) for a gas turbine engine includes removing an engine-run cooling baffle (28A-28D) from the vane segment (20), forming a non-engine-run manufacturing detail that includes an inner platform (22), an outer platform (24), and an airfoil (26), attaching the engine-run cooling baffle (28A-28D) to the non-engine-run manufacturing detail, and marking the non-engine-run manufacturing detail with a serial number associated with the vane segment (20) from which the engine-run cooling baffle (28A-28D) was removed.