IPC分类号：
B22F5/04 | B22F7/08 | B22F10/25 | B22F10/66 | B23K26/342 | B33Y10/00 | F01D5/00 | G01N23/046 | B23P6/00 | B22F7/06 | B22F12/90 | B22F10/80 | B33Y30/00 | B33Y40/20 | B33Y50/00 | B23K1/00
国民经济行业分类号：
C3516 | C3252 | C3251 | C3393
当前申请(专利权)人：
PRATT & WHITNEY CANADA CORP.
原始申请(专利权)人：
PRATT & WHITNEY CANADA CORP.
当前申请(专利权)人地址：
1000 Marie Victorin, (01BE5),Longueuil, Québec J4G 1A1,CA
发明人：
DAULTON, CHARLES TRENT | TRACY, KEVIN M.
摘要：
A method of overhaul of a component (20) includes a) scanning a component (20) using computed tomography to provide scanned data, b) comparing the scanned data to reference data to provide additive manufacturing data, c) depositing material (62A, 62B) on the component (20) using an additive manufacturing device (24) based upon the additive manufacturing data to provide a first obj ect, d) determining predicted characteristics of the first object based upon the additive manufacturing data developed in step b) and the scanned data of step a), e) comparing the predicted characteristics of the first object to the reference data to provide machining data and f) machining the first object using the machining data. A system for overhauling a component is also disclosed.
技术问题语段：
The technical issues addressed in this patent text are related to the repair of complex components. The current methods for repairing these components are expensive and time-consuming.
技术功效语段：
The technical efficacy of this patent is that it provides a method for overhauling a component using a combination of CT scanning, additive manufacturing, and machining. This method allows for the repair of complex components in a cost-effective and efficient manner.
权利要求：
1. A method of overhaul of a component, comprising: a) scanning a component (20) using computed tomography to provide scanned data; b) comparing the scanned data to reference data to provide additive manufacturing data; c) depositing material (62A, 62B) on the component (20) using an additive manufacturing device (24) based upon the additive manufacturing data to provide a first object; d) determining predicted characteristics of the first object based upon the additive manufacturing data developed in step b) and the scanned data of step a); e) comparing the predicted characteristics of the first object to the reference data to provide machining data; and f) machining the first object using the machining data.
2. The method as set forth in claim 1, wherein the reference data comprises data from a design specification for the component (20).
3. The method as set forth in claim 1 or 2, wherein the depositing of the material (62A, 62B) in step c) fills a void (22) in the component (20).
4. The method as set forth in claim 3, wherein the depositing of the material (62A, 62B) in step c) also forms a cladding over a substrate (42) of the component (20).
5. The method as set forth in claim 4, wherein a first material is utilized to fill the void (22), and a second different material is utilized to form the cladding (123).
6. The method as set forth in any preceding claim, wherein the depositing of the material (62A, 62B) forms a cladding over a worn surface (124) on the component (20).
7. The method as set forth in any preceding claim, further comprising removing a residual coating (27) from the component (20) to expose a surface prior to step c).
8. The method as set forth in any preceding claim, wherein step c) includes depositing braze powder on the component (20) and heating the braze material (62A, 62B) with a laser (34) to sinter the braze material (62A, 62B).
9. The method as set forth in claim 8, wherein after the sintering of step c), the component (20) is then put through a heat cycle to melt the braze material (62A, 62B).
10. The method as set forth in any preceding claim, wherein the machining of step f) removes some of the material (62A, 62B) deposited during step c).
11. The method as set forth in any preceding claim, further comprising coating a surface of a second object, wherein the second object is formed by the machining of the first object in step f).
12. The method as set forth in any preceding claim, wherein the component (20) is from a gas turbine engine.
13. A system for overhauling a component (20) comprising: a scanning device (103) configured to scan a component (20) using computed tomography and provide scanned data indicative of one or more characteristics of the component (20); an additive manufacturing device (24) configured to deposit material (62A, 62B) on the component (20) to provide a first object, with the additive manufacturing device (24) controlled by additive manufacturing data; a machining device (102) configured to remove material (62A, 62B) from the first object based upon machining data; and a controller (100) programmed to compare the scanned data with reference data to provide the additive manufacturing data, and the controller (100) further programmed to compare the scanned data (106) along with the additive manufacturing data to develop the machining data.
14. The system as set forth in claim 13, wherein the deposited material (62A, 62B) is braze powder and including a laser (34) to sinter the braze material (62A, 62B).
15. The system as set forth in claim 13 or 14, wherein a laser (34) is provided to sinter the material (62A, 62B) and the system including a furnace (26) such that the component (20) can put in the furnace (26) where a heat cycle melts the braze material (62A, 62B).