SYSTEM AND METHOD FOR REPAIR OF CAST COMPONENT

• US 20150159585A1
• Filed: 12/06/2013
• Published: 06/11/2015
• Est. Priority Date: 12/06/2013
• Status: Abandoned Application

• Current Assignee: Caterpillar Incorporated
• Original Assignee: Caterpillar Incorporated
• Inventors: Kinney, Christopher A., Simpson, Trent A., Parnell, Thomas, Graham, Curtis J., Rasmussen, Benjamin J., Luick, Kegan J., Rice, Bradley
• Application Number:
  US14/098,669
• Publication Number:
  US 20150159585A1
• Time in Patent Office: Days
• US Class Current: 1/1
• CPC Class Codes: B22D 19/10 Repairing defective or damaged objects by metal casting procedures by other procedures B23P6/04; ingot mould B22D7/06; B22D19/06 takes precedence
• CPC Class Codes: B23P 6/02 Pistons or cylinders
• CPC Class Codes: B23P 6/04 Repairing fractures or cracked metal parts or products, e.g. castings
• CPC Class Codes: F02F 7/0002 Cylinder arrangements
• CPC Class Codes: Y10T 428/12347 Plural layers discontinuously bonded [e.g., spot-weld, mechanical fastener, etc.]
• CPC Class Codes: Y10T 428/12493 Composite; i.e., plural, adjacent, spatially distinct metal components [e.g., layers, joint, etc.]

Abstract

A method for repairing a cast component having a damaged area is provided. The method includes scanning an area adjacent to the damaged area to create a scan. The method includes forming a dam with a void. The void has a profile corresponding to the scan. The method includes positioning the dam adjacent to the damaged area. The method includes heating the cast component. The method includes introducing a repair material into the dam. The method also includes cooling the cast component. The method further includes removing an excess material from the cast component.

Claims

1. A method for repairing a cast component having a damaged area, the method comprising:

scanning an area encompassing the damaged area to create a scan;

forming a dam with a void, the void having a profile corresponding to the scan;

positioning the dam adjacent to the damaged area;

heating the cast component;

introducing a repair material into the dam;

cooling the cast component; and

removing an excess material from the cast component.

2. The method of claim 1, wherein the excess material includes at least one of a portion of the dam and a portion of the repair material.

3. The method of claim 1, wherein at least a portion of the repair material is in molten form.

4. The method of claim 1, wherein the heating step further includes:

raising a temperature of the cast component to a first predetermined temperature, the first predetermined temperature is lower than a melting point of a metal of the cast component; and

raising a temperature of the damaged area to a second predetermined temperature, the second predetermined temperature being higher than the first predetermined temperature.

5. The method of claim 1, wherein the heating step further includes heating the dam.

6. The method of claim 5 further comprising:

fusing the dam and the repair material therein with the cast component prior to the cooling.

7. The method of claim 1, wherein the positioning step further includes affixing, removably, the dam onto the cast component using mechanical fasteners.

8. The method of claim 1, wherein the removal step further includes machining the repair material to cooperate with the cast component.

9. The method of claim 1, wherein the area encompassing the damaged area is scanned using at least one of mechanical, optical and laser techniques.

10. An engine block comprising:

a main body casting; and

a repaired portion integrated with the main body, wherein the repaired portion is made of a repair material such that the repair material is introduced into a dam positioned adjacent to a damaged area of the main body, such that the dam is formed to include a void, the void having a profile which matches a scan, wherein the scan is created by scanning an area encompassing the damaged area.

11. The engine block of claim 10, wherein the dam is consumed into the repaired portion.

12. The engine block of claim 10, wherein the dam is made of a ceramic or a metal.

13. A cast component repaired by a process comprising the steps of:

scanning an area encompassing a damaged area to create a scan;

forming a dam with a void, the void having a profile corresponding to the scan;

positioning the dam adjacent to the damaged area;

heating the cast component;

introducing a repair material into the dam;

cooling the cast component; and

removing an excess material from the cast component.

14. The cast component of claim 13, wherein the excess material includes at least one of a portion of the dam and a portion of the repair material.

15. The cast component of claim 13, wherein at least a portion of the repair material is in molten form.

16. The cast component of claim 13, wherein the heating step further includes:

raising a temperature of the cast component to a first predetermined temperature, the first predetermined temperature is lower than a melting point of a metal of the cast component; and

raising a temperature of the damaged area to a second predetermined temperature, the second predetermined temperature being higher than the first predetermined temperature.

17. The cast component of claim 13, wherein the heating step further includes heating the dam.

19. The cast component of claim 13, wherein the positioning step further includes affixing, removably, the dam onto the cast component using mechanical fasteners.

20. The cast component of claim 13, wherein the removal step further includes machining the repair material to cooperate with the cast component.

18. The cast component 17, wherein the process further comprises the step of:

fusing the dam and the repair material therein with the cast component prior to the cooling.