Progress towards printing an engine casing using laser direct energy deposition

Laser Direct Energy Deposition (LDED) is a good candidate Additive Manufacturing (AM) technique for the printing of large parts because it is not constricted through using a powder bed. TWI has been progressing towards printing an engine casing for a number of years, looking to develop and combine the various shapes and techniques needed. These include the creation of large (greater than 1m diameter) rings with various wall thicknesses (up to 10mm if needed), overhanging these walls to specific designs, and the creation of external features such as bosses of various sizes. All of these builds need to also have high material integrity because of the operating conditions of the potential end use component. This starts with achieving material density, with other properties such as static mechanical, fatigue and corrosion resistance a necessity.

This presentation will cover developments in Inconel 718 LDED for the printing of large parts that replicate an aerospace jet engine casing, with some supporting materials data.