Adaptive overhaul with two braze material and CT scans
A method of overhaul of a component includes comparing a component to reference data to provide additive manufacturing data. Depositing material on the component using an additive manufacturing device based upon the additive manufacturing data to provide a first object. The depositing of material includes initially depositing a first material having a relatively high melting point, and then depositing a second material which has a melting point lower than the relatively high melting point of the first material. The depositing step further including heating the first and second materials with a laser to sinter the materials to the component. Putting the component into the furnace for a heat cycle. Then determining predicted characteristics of the first object, and comparing the predicted characteristics of the first object to the reference data to provide machining data. Then machining the first object using the machining data. A system for overhauling a component is also disclosed.
1 . A method of overhaul of a component, comprising:
a) comparing a component to reference data to provide additive manufacturing data;
b) depositing material on the component using an additive manufacturing device based upon the additive manufacturing data to provide a first object, the depositing of material includes initially depositing a first material having a relatively high melting point, and then depositing a second material which has a melting point lower than the relatively high melting point of the first material, with the depositing step further including heating the first and second materials with a laser to sinter the materials to the component, then putting the component into a furnace for a heat cycle;
c) determining predicted characteristics of the first object;
d) comparing the predicted characteristics of the first object to the reference data to provide machining data; and
e) machining the first object using the machining data.
2 . The method as set forth in claim 1 , wherein step a) includes scanning the component.
3 . The method as set forth in claim 2 , wherein the step a) scanning uses computed tomography.
4 . The method as set forth in claim 3 , wherein step c) includes scanning the component again utilizing computed tomography to provide second scan data.
5 . The method as set forth in claim 1 , wherein the reference data comprises data from a design specification for the component.
6 . The method as set forth in claim 1 , wherein the second material fills a void in the component.
7 . The method as set forth in claim 6 , wherein the first material forms a cladding over a substrate of the component.
8 . The method as set forth in claim 1 , wherein the first material forms a cladding over a substrate of the component.
9 . The method as set forth in claim 1 , further comprising removing a residual coating from the component to expose a surface prior to step b).
10 . The method as set forth in claim 1 , wherein the machining of step f) removes some of the material deposited during step c).
11 . The method as set forth in claim 1 , wherein the component is from a gas turbine engine.