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Damage detection and reconstruction algorithm in repairing compressor blade by direct metal deposition

Aero-engine blade repair is challenging due to its complicated geometry and unique defects after serving in a harsh environment. Traditional manual-based remanufacturing processes are not capable of yielding consistently repaired part quality, significantly limiting the application of repair technol... Full description

Journal Title: International journal of advanced manufacturing technology 2017-11-23, Vol.95 (5-8), p.2393-2404
Main Author: Zhang, Xinchang
Other Authors: Li, Wei , Liou, Frank
Format: Electronic Article Electronic Article
Language: English
Subjects:
Publisher: London: Springer London
ID: ISSN: 0268-3768
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recordid: cdi_proquest_journals_2490846048
title: Damage detection and reconstruction algorithm in repairing compressor blade by direct metal deposition
format: Article
creator:
  • Zhang, Xinchang
  • Li, Wei
  • Liou, Frank
subjects:
  • 3D printing
  • Aerospace engineering
  • Algorithms
  • Analysis
  • Automation
  • Blades
  • CAE) and Design
  • Compressor blades
  • Computer-Aided Engineering (CAD
  • Construction materials
  • Damage assessment
  • Damage detection
  • Deposition
  • Engineering
  • Hard surfacing
  • Industrial and Production Engineering
  • Jet engines
  • Laser applications
  • Mechanical Engineering
  • Media Management
  • Original Article
  • Reconstruction
  • Remanufacturing
  • Repair
  • Reverse engineering
  • Titanium base alloys
  • Tracks (paths)
ispartof: International journal of advanced manufacturing technology, 2017-11-23, Vol.95 (5-8), p.2393-2404
description: Aero-engine blade repair is challenging due to its complicated geometry and unique defects after serving in a harsh environment. Traditional manual-based remanufacturing processes are not capable of yielding consistently repaired part quality, significantly limiting the application of repair technologies. For building up materials on damaged blades, it is required to detect and extract the repair volume and generate corresponding tool path for additive manufacturing. Therefore, the objective of this paper is to propose an automated damage detection and reconstruction algorithm for jet engine blade repair. Reverse engineering was utilized to reconstruct models of nominal and damaged blades. The reconstructed damaged model was best fitted with the nominal model by transformation matrix and using overlapping area comparison method. Through area comparison method, the damaged blade was separated into intact section and damaged section. A set of parallel and equidistant casting rays were used to intersect with damaged layers to extract the repair volume. Laser scanning tracks were generated according to the extracted geometry. The laser-assisted direct metal deposition process was performed to deposit Ti-6Al-4V particles on the damaged region. Finally, microstructure analysis was carried out to evaluate the repaired part quality. The repair experiment validated that the proposed algorithm is suitable and efficient for automated repair of curved blades.
language: eng
source:
identifier: ISSN: 0268-3768
fulltext: no_fulltext
issn:
  • 0268-3768
  • 1433-3015
url: Link


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creatorZhang, Xinchang ; Li, Wei ; Liou, Frank
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descriptionAero-engine blade repair is challenging due to its complicated geometry and unique defects after serving in a harsh environment. Traditional manual-based remanufacturing processes are not capable of yielding consistently repaired part quality, significantly limiting the application of repair technologies. For building up materials on damaged blades, it is required to detect and extract the repair volume and generate corresponding tool path for additive manufacturing. Therefore, the objective of this paper is to propose an automated damage detection and reconstruction algorithm for jet engine blade repair. Reverse engineering was utilized to reconstruct models of nominal and damaged blades. The reconstructed damaged model was best fitted with the nominal model by transformation matrix and using overlapping area comparison method. Through area comparison method, the damaged blade was separated into intact section and damaged section. A set of parallel and equidistant casting rays were used to intersect with damaged layers to extract the repair volume. Laser scanning tracks were generated according to the extracted geometry. The laser-assisted direct metal deposition process was performed to deposit Ti-6Al-4V particles on the damaged region. Finally, microstructure analysis was carried out to evaluate the repaired part quality. The repair experiment validated that the proposed algorithm is suitable and efficient for automated repair of curved blades.
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subject3D printing ; Aerospace engineering ; Algorithms ; Analysis ; Automation ; Blades ; CAE) and Design ; Compressor blades ; Computer-Aided Engineering (CAD ; Construction materials ; Damage assessment ; Damage detection ; Deposition ; Engineering ; Hard surfacing ; Industrial and Production Engineering ; Jet engines ; Laser applications ; Mechanical Engineering ; Media Management ; Original Article ; Reconstruction ; Remanufacturing ; Repair ; Reverse engineering ; Titanium base alloys ; Tracks (paths)
ispartofInternational journal of advanced manufacturing technology, 2017-11-23, Vol.95 (5-8), p.2393-2404
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0Springer-Verlag London Ltd., part of Springer Nature 2017
1COPYRIGHT 2018 Springer
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descriptionAero-engine blade repair is challenging due to its complicated geometry and unique defects after serving in a harsh environment. Traditional manual-based remanufacturing processes are not capable of yielding consistently repaired part quality, significantly limiting the application of repair technologies. For building up materials on damaged blades, it is required to detect and extract the repair volume and generate corresponding tool path for additive manufacturing. Therefore, the objective of this paper is to propose an automated damage detection and reconstruction algorithm for jet engine blade repair. Reverse engineering was utilized to reconstruct models of nominal and damaged blades. The reconstructed damaged model was best fitted with the nominal model by transformation matrix and using overlapping area comparison method. Through area comparison method, the damaged blade was separated into intact section and damaged section. A set of parallel and equidistant casting rays were used to intersect with damaged layers to extract the repair volume. Laser scanning tracks were generated according to the extracted geometry. The laser-assisted direct metal deposition process was performed to deposit Ti-6Al-4V particles on the damaged region. Finally, microstructure analysis was carried out to evaluate the repaired part quality. The repair experiment validated that the proposed algorithm is suitable and efficient for automated repair of curved blades.
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abstractAero-engine blade repair is challenging due to its complicated geometry and unique defects after serving in a harsh environment. Traditional manual-based remanufacturing processes are not capable of yielding consistently repaired part quality, significantly limiting the application of repair technologies. For building up materials on damaged blades, it is required to detect and extract the repair volume and generate corresponding tool path for additive manufacturing. Therefore, the objective of this paper is to propose an automated damage detection and reconstruction algorithm for jet engine blade repair. Reverse engineering was utilized to reconstruct models of nominal and damaged blades. The reconstructed damaged model was best fitted with the nominal model by transformation matrix and using overlapping area comparison method. Through area comparison method, the damaged blade was separated into intact section and damaged section. A set of parallel and equidistant casting rays were used to intersect with damaged layers to extract the repair volume. Laser scanning tracks were generated according to the extracted geometry. The laser-assisted direct metal deposition process was performed to deposit Ti-6Al-4V particles on the damaged region. Finally, microstructure analysis was carried out to evaluate the repaired part quality. The repair experiment validated that the proposed algorithm is suitable and efficient for automated repair of curved blades.
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doi10.1007/s00170-017-1413-8