Fraunhofer Institute for Laser Technology IPT, Germany, is developing Selective Laser Melting technology to build aerospace components via additive manufacturing. Step by step laser radiation is scanned across a powder bed and traces out the form of the component within this specific layer. Wherever the laser radiation impacts the powder, the powder initially melts and then solidifies to form a solid mass. In this way, the component is built-up layer by layer.
The researchers are now working with their colleagues from the Fraunhofer Institute for Production Technology IPT on the integration of additive manufacturing into an entire, continuous process chain. To illustrate what the new process chain can achieve, they have produced a Nozzle Guide Vane (NGV) cluster that consists of six double vanes, as shown in the photo. Previously, the vanes for turbines could only be produced in pairs, as twin blades. Now, they can be installed much more easily and quickly.
An important step toward automation of repair is also under development. Called the “CAx framework,” this software approach allows all the various repair technologies to be operated from a single platform. “CA” stands for computer aided, “x” for the individual technologies of the production. First, the geometric data of damaged or worn-out blade is acquired by digitizing. Second, a milling machine blends out the defect; and third, laser radiation builds up the blade again layer by layer via Laser Material Deposition (LMD). The researchers have already implemented this method for gas turbines; now, they can also transfer it to engine blades.
http://www.fraunhofer.de/en/press/research-news
