Turbo Engine Components Repair Methodology by Laser Material Deposition

Abstract

Additive Manufacturing (AM) is an on growing technology in the last decade. Aeronautical industry, among others, is getting involved in this new trend for manufacturing and repairing processes. More concrete inside AM techniques, Laser Metal Deposition (LMD) is a versatile process with the capability of any repairing task, though the use of this technology is considered a multidisciplinary process that requires knowledge of several aspects: 3D digitalization, CAD/CAM programming, and the laser cladding parameters and control. Considering these many challenges, this work states a global vision through all process stages in order to implement LMD repairing technology in several industries. Additionally, trials were performed related to different process stages with significant results serving as initial reference for turbomachinery rotary components repairs. Finally, advantages and drawbacks of LMD process, as well as industrial pioneering companies at this sector. Keywords: Turbomachinery reparation, LMD (Laser Material Deposition), Digitalization, 3D, CAD/CAM, laser cladding, Inconel 718, Hastelloy X, hybrid machines.

Advances in Metal Additive Manufacturing: A Review of Common Processes, Industrial Applications, and Current Challenges

“…For instance, LMD technology was used for fabricating the impeller blades of turbomachinery as well as repairing damaged areas [79]. This metal AM process provides 'Near-Net-Shape' geometry [80]. DED technologies are also used for the repair of turbine airfoils, engine combustion chambers, and blisks [10].…”

Current research and industrial application of laser powder directed energy deposition

“…Moreover, the repair operation using the LP-DED process requires a huge interaction between different disciplines, such as CAD/CAM software and inspection systems, and a high level of operators' knowledge [62].…”

“…According to Ruiz-Salas et al [62] and Yilmaz et al [63], the repair operation of a damaged component follows these different steps: In the following paragraphs, the main achievements of repair operation using the LP-DED process are described, highlighting the industrial sector that are the aerospace sector, the tooling sector, and the other sectors.…”

Manufacturing Processes of Integral Blade Rotors for Turbomachinery, Processes and New Approaches

“…In both, direct blade manufacturing and damaged component repair through LMD [39], a posterior stage of machining is required to achieve the final desired geometry accomplishing tolerance requirements. Hence, this additive manufacturing process provides an initial geometry closer to the final geometry, so it is addressed inside the "Near-Net-Shape" concept [40].…”

“…For repairing operations, LMD process requires previous stages: component damaged area inspection, repairing tool-path strategy definition, studying repairing necessities and feasibility and, finally, a measuring and control stage for the final obtained geometry and the material properties [39]. In both, direct blade manufacturing and damaged component repair through LMD [40], a posterior stage of machining is required to achieve the final desired geometry accomplishing tolerance requirements. Hence, this additive manufacturing process provides an initial geometry closer to the final geometry, so it is addressed inside the "Near-Net-Shape" concept [41].…”