Precise additive fabrication of wall structure on thin plate end with interlayer temperature monitoring

Abstract

Turbine blades need to be repaired to extend their product life, because they are used in highly heated centrifugal fields and often suffer damage such as cracks, chippings, and oxidation thinning. The objective of this study is to perform additive fabrication onto the thin end of a plate using wire and arc-based additive manufacturing and the conduct finish cutting to repair turbine blades made of Inconel 718. It was successfully demonstrated to fabricate a wall structure onto the thin end of a plate with a thickness of 1 to 5 mm with the aimed deposition width while maintaining a constant interlayer temperature. In addition, a finish cutting was conducted on the additionally fabricated wall structure to achieve the same thickness as the thin base plate. It was also shown that there was almost no uncut part on the additive wall surface.

Forming accuracy improvement in wire arc additive manufacturing (WAAM): a review

“…In this regard, k-type thermocouples can be used as they are reasonably priced and offer high measurement efficiency (Montevecchi et al , 2018; Xiong et al , 2018; Langelandsvik et al , 2020). Additionally, optical temperature sensors allow the contactless capturing of the temperature distribution over an area, which is efficient but cost prohibitive (Tsurumaki et al , 2019; Richter et al , 2021; Kozamernik et al , 2020). Figure 8 shows the temperature distribution of the deposited layers.…”

Review of Aluminum Alloy Development for Wire Arc Additive Manufacturing

“…The possibility to maintain and repair components instead of scrapping them induces major benefits in terms of cost and environmental impact. Turbine blades were projected as a suitable recipient for WAAM maintenance [ 13 ]. The Norwegian energy company Equinor initiated pipeline maintenance with their WAAM system Weldar [ 14 ].…”