Laser Metal Deposition as Repair Technology for a Gas Turbine Burner Made of Inconel 718

Petrat, T.; Graf, Benjamin; Gumenyuk, Andrey; Rethmeier, Michael

doi:10.1016/j.phpro.2016.08.078

Cited by 90 publications

(29 citation statements)

References 11 publications

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“…The applications of LMD in industry have been growing in recent years [1][2][3][4]. For its development, research nowadays involves all kinds of areas, such as process optimization [5][6][7][8][9], modelling/simulation [10][11][12][13][14], and material microstructure and mechanical properties [15][16][17][18][19].…”

Section: Introductionmentioning

confidence: 99%

The Influence of the Powder Stream on High-Deposition-Rate Laser Metal Deposition with Inconel 718

Chen

Pirch

Gasser

et al. 2017

Metals

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Abstract:For the purpose of improving the productivity of laser metal deposition (LMD), the focus of current research is set on increasing the deposition rate, in order to develop high-deposition-rate LMD (HDR-LMD). The presented work studies the effects of the powder stream on HDR-LMD with Inconel 718. Experiments have been designed and conducted by using different powder feeding nozzles-a three-jet and a coaxial powder feeding nozzle-since the powder stream is mainly determined by the geometry of the powder feeding nozzle. After the deposition trials, metallographic analysis of the samples has been performed. The laser intensity distribution (LID) and the powder stream intensity distribution (PID) have been characterized, based on which the processes have been simulated. Finally, for verifying and correcting the used models for the simulation, the simulated results have been compared with the experimental results. Through the conducted work, suitable boundary conditions for simulating the process with different powder streams has been determined, and the effects of the powder stream on the process have also been determined. For a LMD process with a three-jet nozzle a substantial part of the powder particles that hit the melt pool surface are rebounded; for a LMD process with a coaxial nozzle almost all the particles are caught in the melt pool. This is due to the different particle velocities achieved with the two different nozzles. Moreover, the powder stream affects the heat exchange between the heated particles and the melt pool: a surface boundary condition applies for a powder stream with lower particle velocities, in the experiment provided by a three-jet nozzle, and a volumetric boundary condition applies for a powder stream with higher particle velocities, provided by a coaxial nozzle.

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Section: Introductionmentioning

confidence: 99%

The Influence of the Powder Stream on High-Deposition-Rate Laser Metal Deposition with Inconel 718

Chen

Pirch

Gasser

et al. 2017

Metals

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“…Similarly, defects in end-of-life marine components such as the crankpin journal surface consist of ridges, cuts, and grooves that are restored through grinding on a stationary machine [27]. Likewise, in the aerospace or aircraft industry, remanufacturing involves the repair of landing gear parts and flight surface actuators as well as rebuilding chipped parts of gas turbines [20,28].…”

Section: Producers Output Value (In Usd)mentioning

confidence: 99%

“…The progress in AM application today is depicted in Figure 2. in the aerospace or aircraft industry, remanufacturing involves the repair of landing gear parts and flight surface actuators as well as rebuilding chipped parts of gas turbines [20,28]. With the advancement of technologies, it is foreseen that the manual reparation processes of remanufacturable products can be possibly replaced by digital restoration such as additive manufacturing (AM) as the primary option [29][30][31].…”

Section: Producers Output Value (In Usd)mentioning

confidence: 99%

Additive Manufacturing for Repair and Restoration in Remanufacturing: An Overview from Object Design and Systems Perspectives

2019

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Repair and restoration is an important step in remanufacturing as it ensures end-of-life products are returned to as-new condition before entering the subsequent life cycle. Currently, such processes are carried out manually by skilled workers. The advent of additive manufacturing (AM) has encouraged researchers to investigate its potential in automated repair and restoration, thus rendering it as a more effective method for remanufacturing. However, the application of this widespread technology for repair and restoration in remanufacturing is still new. This paper provides an overview of the principles and capabilities offered by the existing metal AM technology for object repair and restoration namely, direct energy deposition, powder bed fusion, and cold spray technology. Their applications in the repair and restoration of remanufacturable components are presented and discussed along with issues requiring attention from the perspectives of object design and process systems capabilities. The study provides a compilation of the challenges in AM repair and restoration, which primarily lie in the aspects of geometrical complexity, geometric dimensioning and tolerancing, material compatibility, and pre-processing requirements since it is critical for remanufacturing to restore end-of-life components to as new-condition. The paper concludes with suggestions for further works in AM restoration to enable product life cycle extension in the circular economy.

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“…Powder bed fusion (PBF) and directed-energy-deposition (DED) are the two most widely-employed techniques for printing functional metal components. (A) Pure-Copper component manufactured via EBM with internal core structure [127] (B) Porous Nickel-Titanium shape-memory structure enabled via SLM [128] (C) LMD (or DED) repair of SLM-based Inconel 718 fuel burner [39] (D) Porous Ti6Al4V components enabled via SLM technique [129] (E) Structurally-optimized titanium-alloy component enabled via SLM [122] (F) Titanium hip stems manufactured via EBM [130]. …”

Section: Figurementioning

confidence: 99%

Invited review article: Metal-additive manufacturing—Modeling strategies for application-optimized designs

Bandyopadhyay

Traxel

2018

Additive Manufacturing

123

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Next generation, additively-manufactured metallic parts will be designed with application-optimized geometry, composition, and functionality. Manufacturers and researchers have investigated various techniques for increasing the reliability of the metal-AM process to create these components, however, understanding and manipulating the complex phenomena that occurs within the printed component during processing remains a formidable challenge—limiting the use of these unique design capabilities. Among various approaches, thermomechanical modeling has emerged as a technique for increasing the reliability of metal-AM processes, however, most literature is specialized and challenging to interpret for users unfamiliar with numerical modeling techniques. This review article highlights fundamental modeling strategies, considerations, and results, as well as validation techniques using experimental data. A discussion of emerging research areas where simulation will enhance the metal-AM optimization process is presented, as well as a potential modeling workflow for process optimization. This review is envisioned to provide an essential framework on modeling techniques to supplement the experimental optimization process.

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Laser Metal Deposition as Repair Technology for a Gas Turbine Burner Made of Inconel 718

Cited by 90 publications

References 11 publications

The Influence of the Powder Stream on High-Deposition-Rate Laser Metal Deposition with Inconel 718

The Influence of the Powder Stream on High-Deposition-Rate Laser Metal Deposition with Inconel 718

Additive Manufacturing for Repair and Restoration in Remanufacturing: An Overview from Object Design and Systems Perspectives

Invited review article: Metal-additive manufacturing—Modeling strategies for application-optimized designs

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