Applying a cladding layer to a surface of a component using a cladding tool having a maximum reach less than the size of the surface

An apparatus for applying a cladding layer to a surface of a component using a cladding tool having a maximum reach less than the size of the surface, the apparatus comprising:

• a computer storing a 3-dimensional computer model of the component, including geometry of the surface to be clad;
• and
• a cladding tool configured to deposit the cladding layer as a bead applied to a surface of the component,
• wherein the computer is configured to:
• generate a point distribution from the geometry of the surface, the point distribution including a plurality of points having a separation determined by a maximum reach of the cladding tool;
• generate a plurality of tessellated segments from the point distribution, each tessellated segment having a peripheral extent determined by a maximum reach of the cladding tool;
• generate a nominal tool subpath for each one of the plurality of tessellated segments;
• generate a nominal tool path for depositing the cladding layer on the surface of the component by combining the nominal tool subpaths;
• instruct the cladding tool to deposit the cladding layer on the surface of the component by instructing the tool to move along the nominal tool path while applying the cladding layer bead;
• measure dimensions of a cladding layer bead previously deposited by the tool;
• adjust the nominal tool path to an adjusted tool path that accounts for dimensions of the bead to be deposited by the tool to match an edge of the bead to be deposited with an edge of a previously deposited bead;
• and
• continue to instruct the tool to deposit the cladding layer on the surface of the component by instructing the tool to move along the adjusted tool path.

A non-transitory computer-readable medium having instructions encoded thereon executable by a computer that, when executed by the computer, cause the computer to perform a method of applying a cladding layer to a surface of a component using a cladding tool having a maximum reach less than the size of the surface, the method comprising:

• providing a 3-dimensional model of the component, the model including geometry of the surface to be clad;
• generating a point distribution from the geometry of the surface, the point distribution including a plurality of points having a separation determined by a maximum reach of the cladding tool;
• generating a plurality of tessellated segments from the point distribution, each tessellated segment having a peripheral extent determined by a maximum reach of the cladding tool;
• generating a nominal tool subpath for each one of the plurality of tessellated segments;
• generating a nominal tool path for depositing the cladding layer on the surface of the component by combining the nominal tool subpaths;
• positioning a the cladding tool adjacent a the surface of the component, the tool being configured to deposit the cladding layer as a bead applied to the surface of the component;
• depositing the cladding layer on the surface of the component by instructing cladding the tool to move along the nominal tool path;
• measuring dimensions of a bead of cladding layer previously deposited by the tool;
• adjusting the nominal tool path to an adjusted tool path that accounts for dimensions of the bead to be deposited by the tool to match an edge of the bead to be deposited with an edge of a previously deposited bead;
• and
• continuing to deposit the cladding layer on the surface of the component by instructing the tool to move along the adjusted tool path.