Challenges in Qualifying Additive Manufacturing for Turbine Components: A Review

Srinivasan, Dheepa

doi:10.1007/s12666-021-02199-5

Cited by 9 publications

(2 citation statements)

References 102 publications

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“…The aircraft casing, known as the engine's "skeleton", serves as its primary loadbearing part. With its large size, intricate structure, thin walls, and high precision requirements, it necessitates advanced precision casting techniques [1]. Surface defects are inevitable during the casting of titanium alloy casings, leading to the formation of casting process holes.…”

Section: Introductionmentioning

confidence: 99%

The Engine Casing Machining Holes Repairing Based on Vibration Wire Feeding

Pan,

Gao,

et al. 2024

Metals

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The engine casing components operate in high-temperature and high-pressure environments. Process holes are drilled when defects occur. Welding is employed in the repair of process holes as a process for permanently joining materials. The traditional welding method relies on padding, which results in poor back formation of process holes. Additionally, the shape of the process holes imposes high requirements on the size of the droplet transition. The conventional approach of adjusting a welding current makes it difficult to achieve stable droplet transition and precise formation of small holes. It poses a challenge for the robotic welding process. To deal with this problem, the influence of the high-frequency vibration GTAW process on the directional transition of molten droplets is studied. The molten droplet directional transition process is developed. The impact of vibration energy on the molten pool is reduced. Welding repair experiments for process holes are successfully conducted. When the frequency is 3 Hz, the transition of droplets changes from a continuous one-droplet transition to a discontinuous liquid bridge transition. The residual height and mechanical properties of the repaired area are tested. The experimental results indicated that the residual height after dual-side repair is ≤0.7 mm. The X-ray and fluorescent penetration tests have a 100% first-pass qualification rate. The repaired area demonstrates a hardness of 480 HV and a room-temperature tensile strength of 1069 MPa. The repair process requirements for the casing are met.

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Section: Introductionmentioning

confidence: 99%

The Engine Casing Machining Holes Repairing Based on Vibration Wire Feeding

Pan,

Gao,

et al. 2024

Metals

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“…Replacement of failed components with new parts is one of the main strategies in repair and maintenance management systems [1]. The spare parts supply chain in the operating and maintenance (O&M) process is of great importance for offshore industries, as any delay in spare parts supply can be the cause of a substantial increase in costs due to increased shutdown times, loss of production, and labor work [2]. Warehousing and capital costs make it uneconomic to store all spare parts in stock, therefore, the introduction of alternative technologies for the supply chain process is essential.…”

Section: Introductionmentioning

confidence: 99%

Development of a Procedure for Risk-Based Qualification of Additively Manufactured Components: Adopting to Oil and Gas Industrial Applications

et al. 2022

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Recent advances in additive manufacturing (AM) technology provide the potential for on-demand and rapid production of spare parts during urgent repair times. Recently, big oil and gas companies have shown early progress in using additive technology in manufacturing specific heat exchangers, downhole cleanout tool nozzles, offshore risers, gas turbine nozzles, and subsea chemical stick injection tools. Despite the mentioned progress, the current adoption level of additive technology for the offshore oil and gas industry is very limited. Non-destructive and destructive evaluation methods of additively manufactured metallic components have been studied extensively. However, the technique selection procedure and scope of the required test methods have not been studied sufficiently. This paper discusses various elements related to the qualification of additively manufactured components for application in the oil and gas industry. A risk-based qualification method for identifying the scopes of required non-destructive and destructive tests and the resulting qualification procedure for additively manufactured spare components in offshore oil and gas applications is suggested.

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