Optomec, Albuquerque, N.M., calculates that 100+ customer installations using its 3D metal printers specifically for gas turbine component repair, have refurbished more than ten million turbine blades.
The company’s metal additive repair machines are installed at all leading gas turbine OEMs, in both the aviation market for aircraft engines, and the energy market for power generation. Additionally, many of the third party maintenance repair and overhaul (MRO) shops also use Optomec systems.
The solutions include its Huffman brand five-axis laser cladders, and its LENS brand metal additive 3D printers—both based on directed energy deposition (DED) technology that Optomec was first to bring to market. Common production applications include the repair of turbine blade tips, seals, and wear surfaces; compressor blades, including titanium alloys; vanes, shrouds, and other high-value components.
The automated solution typically replaces manual operations, such as tungsten inert gas (TIG) welding, and drastically reduces the cost of routine maintenance. The ROI of Optomec’s machinery has been recently calculated to be in excess of 180%. In addition, its laser-based processing provides superior mechanical performance due to its optimal metallurgy and minimal heat input, compared to manual operations.
Customers benefit specifically from innovations in the following critical areas: 1) proprietary vision and adaptive control software 2) controlled inert atmosphere processing for superior metallurgy 3) turn-key repair process recipes and 4) automation solutions that enable higher throughput batch processing.
