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Wednesday, May 17, 2006 - 1:30 PM
EMP063.1

Additive Repair Using the LENS Process

D. Keicher, R. Grylls, R. Plourde, T. Marchione, Optomec, Inc., Albuquerque, NM

Repairs of high-value metal components can be made in a number of ways.  Methods that add material to worn or damaged areas primarily use either wire or powder feed material, and either welding or laser-based power sources.  The Laser Engineered Net Shaping (LENS®) process is a laser-powder additive manufacturing system that has been adapted over recent years to be optimized also for repair of metal components.  Because of it’s adaptation from an additive manufacturing technique, and it’s use of a Nd:YAG laser, it offers several advantages over other techniques in making various repairs.  This paper will describe recent advances in the technology's equipment, controls and capabilities, including the introduction of new fiber-lasers.  Several case studies will be described, including demonstration repairs of compressor airfoils, and test results showing the microstructural features and mechanical properties of the added material.  Demonstrated Return-on-Investment for repair applications will also be discussed.  LENS is a registered trademark of Sandia National Laboratories and Sandia Corporation.

Summary: This paper will describe recent advances in the state-of-the-art of the LENS additive manufacturing process as it related to repair of high-value components. Particular emphasis will be placed on recent equipment advances, and recent applications development in the aerospace field.