X-ray Anode Repair via Interdiffusion Annealing
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Solution Overview
Problem
Existing methods for repairing x-ray anode target coatings are inadequate as they result in fragile repaired sections, which do not effectively address thermomechanical stress-induced degradation and spatial dispersion of x-rays, leading to reduced x-ray power and efficiency.
Innovation Solution
A process involving machining of the initial target coating to create a residual layer, followed by deposition of an intermediate and repairing layer, and a heat treatment for interdiffusion and solid solution formation, eliminating internal interfaces and enhancing adhesion and thermal contact between layers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If vapor phase deposition or powder sintering is used to fill damaged sections, then the target coating can be restored, but the repaired sections become fragile and do not withstand thermomechanical stresses
Solution Approach 1:
A transition layer made of rhenium or tungsten-rhenium alloy is deposited between the residual target coating and the new refractory material layer. This intermediary layer facilitates gradual interdiffusion during heat treatment, creating a solid solution that eliminates sharp interfaces and reduces fragility at the repair boundary.
Solution Approach 2:
The patent employs controlled heat treatment at elevated temperatures (1200-2000°C) to induce interdiffusion and formation of solid solutions between the transition layer and adjacent layers. This parameter change transforms the microstructure from distinct layered interfaces to a gradually transitioning solid solution, significantly improving mechanical integrity.
2Reliability
If material is removed and replaced by brazing, soldering or welding, then damaged sections can be replaced, but the disc requires extensive working and positioning becomes problematic
Solution Approach 1:
The patent extracts only the damaged superficial layer of the target coating through machining, preserving the intact residual layer beneath. This selective removal avoids the need to extract or reposition the entire disc, simplifying the repair process while maintaining structural integrity.
Solution Approach 2:
The repair process is segmented into distinct stages: machining the damaged surface, depositing a transition layer, depositing the new refractory material layer, and performing controlled heat treatment. This segmentation allows each step to be optimized independently, reducing overall process complexity compared to monolithic replacement methods.
3Ease of manufacture
If multiple layers are deposited without interdiffusion, then repair can be performed, but fragile interfaces remain between layers
Solution Approach 1:
The patent employs controlled heat treatment at elevated temperatures (1200-2000°C) to induce interdiffusion and formation of solid solutions between the transition layer and adjacent layers. This parameter change transforms the microstructure from distinct layered interfaces to a gradually transitioning solid solution, significantly improving mechanical integrity.
Solution Approach 2:
The patent creates a composite structure with a transition layer made of rhenium or tungsten-rhenium alloy between the residual target coating and the new refractory material layer. This composite approach, combined with interdiffusion, creates a gradient structure that eliminates sharp interfaces and enhances overall strength and adhesion.
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
The process results in a robust, efficient x-ray anode with improved thermal contact and adhesion, reducing fragile interfaces and enhancing the durability and performance of the repaired anode.
Implementation Method 1
an anneal is carried out such that, by interdiffusion and formation of a solid solution, the material of said intermediate part and the material of said residual annular part diffuse into each other
Implementation Method 2
formation of a solid solution, the material of said intermediate part and the material of said residual annular part diffuse into each other
Implementation Method 3
a step of depositing an intermediate layer on said residual annular layer; a step of depositing a repairing layer on said intermediate layer
Implementation Method 4
a heat treatment step in which an anneal is carried out such that, by interdiffusion and formation of a solid solution
Data Source
AI summary
A process for repairing a damaged annular region of an anode configured to emit x-rays includes the step of machining the damaged annular region made of an initial target coating to a depth smaller than a thickness of the coating so as to leave behind a residual annular layer. An intermediate layer is then deposited on the residual annular layer. A repairing layer is then deposited on the intermediate layer. A heat treatment is then performed using an anneal which causes, by interdiffusion and formation of a solid solution, the material of the intermediate layer and the material of the residual annular layer to diffuse into each other and further cause the material of the intermediate layer and the material of the repairing layer diffuse into each other. As a result of this anneal the intermediate layer disappears.