Water Jet Gap Cleaning for Turbine Crack Repair Prep
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Solution Overview
Problem
Conventional cleaning methods, such as fluoride ion cleaning, are inadequate for removing contaminants and debris from deep cracks and crevices in turbine engine parts, leading to incomplete gap processing and potential premature failure due to residual oxides and contaminants.
Innovation Solution
A process using water jet cleaning with pressurized water, optionally with abrasives, to effectively remove surface contaminants and oxidation layers from deep gaps within turbine engine parts, guided by digital imaging and precise measurement to ensure thorough cleaning without damaging the base material.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional cleaning methods such as fluoride ion cleaning are used, then the cleaning process is simple and quick, but the cleaning effectiveness in deep cracks and crevices is insufficient
Solution Approach 1:
The patent employs hydrodynamic cleaning methods using pressurized fluid jets to remove contaminants from deep cracks and crevices. The hydraulic system delivers high-velocity fluid streams that penetrate into narrow gaps, achieving thorough cleaning where conventional chemical methods fail, while avoiding the need for complex mechanical access equipment.
Solution Approach 2:
The patent replaces conventional chemical cleaning methods (fluoride ion cleaning) with mechanical-hydraulic cleaning using pressurized water or abrasive jets. This substitution enables physical removal of contaminants through fluid dynamics and mechanical impact, achieving superior cleaning effectiveness in deep cracks without relying on chemical reactions that cannot reach deep crevices.
2Ease of operation
If material removal is performed to optimize processing, then access to cracks is improved, but material weakness is introduced
Solution Approach 1:
The patent uses pressurized fluid jets to clean deep cracks and crevices without requiring material removal. The hydraulic cleaning system penetrates into narrow gaps and removes contaminants through fluid impact and erosion mechanisms, providing full access to crack interiors while preserving the integrity of the base material.
Solution Approach 2:
The patent extracts and removes only the contaminants (oxides, debris, impurities) from the cracks and crevices, leaving the base material intact. This selective removal approach cleans the gaps thoroughly without removing any structural material, thereby maintaining the original strength and avoiding introduction of material weakness.
3Productivity
If residual oxides and contaminants remain in cracks, then the part can be processed faster, but premature failure occurs
Solution Approach 1:
The patent employs high-velocity pressurized fluid jets to rapidly remove contaminants from deep cracks and crevices. The hydraulic cleaning process achieves thorough contamination removal in a single step, eliminating the need for multiple cleaning stages and enabling fast processing while ensuring complete removal of oxides and debris that would otherwise cause premature failure.
Solution Approach 2:
The patent performs preliminary cleaning of cracks and crevices using pressurized fluid jets before subsequent processing operations. This preliminary action removes all contaminants and oxides in advance, ensuring that the surfaces are fully prepared for welding or brazing, thereby preventing premature failure while maintaining efficient processing throughput.
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 enhances defect preparation and repair of hard-to-weld superalloy components, minimizing material removal and maintaining optimal mechanical properties, while effectively cleaning deep gaps in turbine parts to prevent premature failure.
Implementation Method 1
A process using water jet cleaning with pressurized water, optionally with abrasives, to effectively remove surface contaminants and oxidation layers from deep gaps within turbine engine parts
Data Source
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AI summary
A process (100) for treating a component (201) comprising the steps of capturing a digital image of a gap (203) in a portion of a component (201). The gap (203) is characterized as having gap walls, a length and at any point along its length as having the features of an inner width between the gap walls, an outer width between the gap walls, and a depth. One or more of such features is measured (102) at one or more points along all or a portion of the length of the gap (203). The measurements are used to determine (103) a water jet cleaning path (300), a cleaning edge (302) relative to a gap wall and path angle. A water jet is passed (104) along all or a portion of the selected path to remove debris and/or a portion of a gap wall. The treated gap (203) is then processed (107) further to join the gap edges using a suitable sealing method.