METHOD FOR REPAIRING AND/OR UPGRADING A COMPONENT OF A GAS TURBINE

• US 20110264413A1
• Filed: 02/18/2011
• Published: 10/27/2011
• Est. Priority Date: 02/22/2010
• Status: Abandoned Application

• Current Assignee: Alstom Technology Ltd. (Alstom SA)
• Original Assignee: Alstom Technology Ltd. (Alstom SA)
• Inventors: Rickenbacher, Lukas Emanuel, Hövel, Simone, Stankowski, Alexander
• Application Number:
  US13/030,301
• Publication Number:
  US 20110264413A1
• Time in Patent Office: Days
• US Class Current: 703/1
• CPC Class Codes: B23P 6/005 using only replacement pieces of a particular form
• CPC Class Codes: F01D 5/005 Repairing methods or devices
• CPC Class Codes: F05D 2230/23 by permanently joining parts together
• CPC Class Codes: F05D 2230/238 Soldering

Abstract

In a method for repairing and/or upgrading a component (10′), preferably of a gas turbine, especially a blade (10′), which component has been deformed during operation, a simplification with cost advantages is achieved by a first nominal CAD model (M1) of the non-deformed component (10) being made available, by the deformed component (10′) being measured, and by the first CAD-model (M1), with the aid of the data determined on the deformed component (10′), being transformed into a second CAD model (M2) of the deformed component (10′) by morphing. A cutting line, which determines a cut-out in the component (10′), and also an insert piece, which can be inserted in the cut-out, is established in the second CAD model (M2). A cut-out is introduced into the component (10′) in accordance with the cutting line, an insert piece for inserting in the cut-out is manufactured in accordance with the cutting line, the manufactured insert piece is inserted in the cut-out, and the inserted insert piece is connected to the component (10′) in a materially bonding manner.

Claims

1. A method for repairing and/or upgrading a component which has been deformed during operation, the method comprising:

obtaining a first nominal CAD model of the non-deformed component;

measuring the deformed component and determining data from the deformed component;

transforming the first CAD model with the data determined from said measuring into a second CAD model of the deformed component, said transforming including morphing;

establishing a cutting line which determines a cut-out in the component and an insert piece which can be inserted into the cut-out, in the second CAD model;

forming a cut-out into the component based on the cutting line;

manufacturing an insert piece for inserting into the cut-out based on the cutting line;

inserting the insert piece from said manufacturing into the cut-out; and

connecting the insert piece after said inserting to the component in a materially bonding manner.

2. The method as claimed in claim 1, wherein:

the component has damage and/or a region which is intended for an upgrade; and

forming a cut-out comprises removing the damage or the region which is intended for the upgrade from the component.

3. The method as claimed in claim 1, wherein measuring the deformed component comprises measuring at least a small number of reference points on said deformed component using a non-destructive method.

4. The method as claimed in claim 3, wherein measuring the deformed component comprises mechanically, optically, or both, scanning using a three-dimensional, external scanning process.

5. The method as claimed in claim 4, wherein:

scanning comprises non-destructively scanning an internal structure of the deformed component, or determining said internal structure based on a small number of reference points; and

said transforming into a second CAD model comprises transforming based on deformations of the internal structure of the component and deformations of cooling holes.

6. The method as claimed in claim 5, wherein non-destructively scanning comprises CT or ultrasonic scanning.

7. The method as claimed in claim 5, wherein said transforming into a second CAD model comprises transforming based on changes as a result of material loss.

8. The method as claimed in claim 7, wherein said transforming based on changes as a result of material loss comprises transforming based on changes in a thickness of walls of the component.

9. The method as claimed in claim 1, wherein forming the cut-out comprises mechanical machining.

10. The method as claimed in claim 9, wherein mechanical machining comprises Electrical Discharge Machining.

11. The method as claimed in claim 1, wherein the insert piece has a geometry which deviates from the geometry of the part which is removed from the cut-out.

12. The method as claimed in claim 1, wherein manufacturing an insert piece comprises manufacturing an insert piece having a geometry based on all internal and external deformations of the component.

13. The method as claimed in claim 1, further comprising:

generating a CAD model for the manufacture of the insert piece based on the cutting line; and

wherein manufacturing the insert piece comprises manufacturing based on the generated CAD model.

14. The method as claimed in claim 13, wherein manufacturing the insert piece based on the generated CAD model comprises casting, an additive manufacturing process, or a mechanical machining process.

15. The method as claimed in claim 14, wherein said mechanical machining process comprises milling or electrochemical machining.

16. The method as claimed in claim 1, wherein manufacturing the insert piece comprises manufacturing the piece oversized at prespecified points, and further comprising:

machining the insert piece after said manufacturing.

17. The method as claimed in claim 1, wherein connecting the inserted insert piece in a materially bonding manner comprises welding.

18. The method as claimed in claim 1, wherein connecting the inserted insert piece in a materially bonding manner comprises high-temperature soldering.

19. The method as claimed in claim 1, further comprising:

machining the component with regard to the external contour after said inserting and after said connecting in a materially-bonding manner.

20. The method as claimed in claim 1, wherein the component is a component of a gas turbine.

21. The method as claimed in claim 1, wherein the component is a blade of a gas turbine.