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Wednesday, May 17, 2006 - 4:00 PM
EMP063.6

Potentials of Highly-Developed Laser Base Techniques for Additive Manufacturing and Repair of Complex Shaped Aero Engine Parts out of Nickel and Titanium Base Alloys

I. Kelbassa, W. Meiners, K. Wissenbach, Fraunhofer Institute Laser Technology, Aachen, Germany; L. Trippe, Chair of Laser Technology, RWTH Aachen, Aachen, Germany

Additive manufacturing and repair techniques like Laser Metal Deposition (LMD) and Selective Laser Melting (SLM) as well as Laser Drilling (LD) are well known applications. The range of processable materials was extended in the last years towards serial aero engine materials like Nickel and Titanium base alloys. Achieved results regarding macro and micro structure, hardness, defects (e. g. cracks, bonding defects, porosity) and contamination with atmospheric elements (e. g. O, N, C and H) are presented for Titanium alloys like Ti-6Al-4V, Ti-6246 and Ti-17 as well as for Nickel base alloys like Inconel 718 and Rene 80. The influences of the process parameters on the achieved results are discussed. Suitable process parameter windows are presented. Achieved static (tensile) and dynamic mechanical properties (HCF) are shown and compared to those of heat treated forged raw materials. Implemented applications are demonstrated and discussed in detail. Based on the results, technological and economical (low-cost manufacturing and repair) potentials of the Laser based techniques are estimated for specific manufacturing and repair cases occurring in the near future in the aero engine field of application. One innovative solution proposal (manufacturing case) is to use a mould for a rotationally symmetrical casing without any geometrical elements on the surface and to fabricate the small and filigrane complex shaped geometrical elements by LMD (Laser Metal Deposition) and / or SLM (Selective Laser Melting). By LMD these elements are built-up directly on the large parts. With SLM the elements are manufactured separately in the SLM machine and connected by a subsequent joining technique with the large parts. With SLM also small complex shaped parts like combustor swirlers, HPT blades and vanes with internal cooling channels can be manufactured completely also in combination with subsequent Laser Drilling (LD).

Summary: Additive manufacturing and repair techniques like Laser Metal Deposition (LMD) and Selective Laser Melting (SLM) as well as Laser Drilling (LD) are well known applications. The range of processable materials was extended in the last years towards serial aero engine materials like Nickel and Titanium base alloys. Materials under investigations are the Titanium base alloys Ti-6Al-4V, Ti-6246 and Ti-17 as well as the Nickel base alloys Inconel 718 and Rene 80. Based on the results achieved, technological and economical (low-cost manufacturing and repair) potentials of the Laser based techniques are estimated for specific manufacturing and repair cases occurring in the near future in the aero engine field of application.